Ford - F 150 4wd Pickup - Workshop Manual - 1999 - 1999

Factory Workshop Manual Make Ford Model F 150 4wd Pickup Engine and year V8-5.4L SOHC VIN 3 (1999) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 ( P 0500 ) P0500 - P0504: Testing and Inspection P0500 ( P 0500 ) For diagnosis of P0500 refer to the system experiencing the problem. Computers and Control Systems or Transmission Control System For the 'F' Series 4x4 U/8500 (MSOF) refer to DP30. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DP - Vehicle Speed/Transfer Case Speed Sensors/DP30 - DP35 For all others refer to DP1. See: Powertrain Management/Computers and Control Systems/Testing and Inspection/Pinpoint Tests/DP - Vehicle Speed/Transfer Case Speed Sensors For complete Engine Control diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Transfer Case ESOF - Electronic Shift on the Fly Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 ( P 0500 ) > Page 9 Part 2 Of 4 MSOF - Mechanical Shift on the Fly Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504, ( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 ( P 0500 ) > Page 10 Part 3 Of 4 For complete Transfer Case diagnostic information, See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > P0720 ( P 0720 ) P0720 - P0724: Testing and Inspection P0720 ( P 0720 ) Manual Transmission (M.T.) For diagnosis of P0720 refer to chart Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > P0720 ( P 0720 ) > Page 16 For complete Engine Control diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Automatic Transmission (A.T.) For diagnosis of P0720 refer to chart Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > P0720 ( P 0720 ) > Page 17 Part 7 Of 8 For complete Transmission Control diagnostic information, See: Powertrain Management/Transmission Control Systems/Testing and Inspection For complete Engine Control diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > P0720 ( P 0720 ) > Page 18 P0720 - P0724: Testing and Inspection P0721 ( P 0721 ) Manual Transmission (M.T.) For diagnosis of P0721 refer to chart Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > P0720 ( P 0720 ) > Page 19 For complete Engine Control diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Automatic Transmission (A.T.) For diagnosis of P0721 refer to chart Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > P0720 ( P 0720 ) > Page 20 Part 7 Of 8 For complete Transmission Control diagnostic information, See: Powertrain Management/Transmission Control Systems/Testing and Inspection For complete Engine Control diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > P0720 ( P 0720 ) > Page 21 P0720 - P0724: Testing and Inspection P0722 ( P 0722 ) Manual Transmission (M.T.) For diagnosis of P0722 refer to chart Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > P0720 ( P 0720 ) > Page 22 For complete Engine Control diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Automatic Transmission (A.T.) For diagnosis of P0722 refer to chart Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724, ( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > P0720 ( P 0720 ) > Page 23 Part 7 Of 8 For complete Transmission Control diagnostic information, See: Powertrain Management/Transmission Control Systems/Testing and Inspection For complete Engine Control diagnostic information, See: Powertrain Management/Computers and Control Systems/Testing and Inspection Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1800 - P1804, ( P1801 P1802 P1803 1800 1801 1802 1803 1804 ) > System Information > System Diagnosis P1800 - P1804: Testing and Inspection For diagnosis of P1804 refer to the system experiencing the problem. Transfer Case ESOF - Electronic Shift on the Fly Refer to Instrument Panel below MSOF - Mechanical Shift on the Fly Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1800 - P1804, ( P1801 P1802 P1803 1800 1801 1802 1803 1804 ) > System Information > System Diagnosis > Page 28 Part 3 Of 4 For complete Transfer Case diagnostic information, See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Instrument Panel Part 3 Of 4 For complete Instrument Panel diagnostic information, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1805 - P1809, ( P1806 P1807 P1808 1805 1806 1807 1808 1809 ) > System Information > System Diagnosis P1805 - P1809: Testing and Inspection For diagnosis of P1806 refer to the system experiencing the problem. Transfer Case ESOF - Electronic Shift on the Fly Refer to Instrument Panel below MSOF - Mechanical Shift on the Fly Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1805 - P1809, ( P1806 P1807 P1808 1805 1806 1807 1808 1809 ) > System Information > System Diagnosis > Page 32 Part 3 Of 4 For complete Transfer Case diagnostic information, See: Transmission and Drivetrain/Transfer Case/Testing and Inspection Instrument Panel Part 3 Of 4 For complete Instrument Panel diagnostic information, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Testing and Inspection Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Accessory Delay Relay: Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 39 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 40 Accessory Delay Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 41 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module > Page 46 Alarm Module: Diagrams Remote Anti-Theft Personality Module Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module > Page 47 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Module Replacement Alarm Module: Service and Repair Module Replacement REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2 Insert a punch in the access hole of the steering column and press the release tab while pushing out the ignition switch lock cylinder. 3. Unscrew and remove the tilt wheel handle and shank. 4. Remove the instrument panel steering column cover. 5. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the lower steering column shroud. 3 Remove the upper steering column shroud. NOTE: The steering wheel has been removed for clarity. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Module Replacement > Page 50 6. Remove the anti-theft transceiver module. 1 Remove the screw from the bottom of the transceiver module. 2 Disconnect the electrical connector and remove the module. NOTE: Only apply pressure or leverage below the key cylinder lower rib. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Module Replacement > Page 51 Alarm Module: Service and Repair Remote Anti-Theft Personality Module REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the LH front door scuff plate. 3. Remove the LH cowl side trim panel. 4. Disconnect the two Remote Anti-Theft Personality (RAP) module electrical connectors. 1 Disconnect C257. 2 Disconnect C256. NOTE: If C256 is disconnected first, an inadvertent IGNTAM alarm event (AL__EVT) will be stored and the alarm will sound. The alarm must be disarmed by the remote unlock button or a key in the door lock cylinder to UNLOCK. To avoid this condition, disconnect (1) C257 before (2) C256 and reconnect (2) C256 before (1) C257. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Module Replacement > Page 52 5. Remove the RAP module nuts and the RAP module. INSTALLATION 1. To install, reverse the removal procedure. NOTE When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. - To avoid inadvertent alarm activation, reconnect C256 first. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Technical Service Bulletins > Customer Interest: > 99-21-3 > Oct > 99 > Autolock System - Functions Not Operating Properly General Module: Customer Interest Autolock System - Functions Not Operating Properly Article No 99-21-3 10/18/99 AUTO-LOCK - AUTO-LOCK FUNCTIONS NOT OPERATING PROPERLY - VEHICLES BUILT FROM 6/3/1999 THROUGH 6/8/1999 FORD: 1999 F-150, F-250 LD ISSUE The Auto-Lock Functions may not be operating properly. This may consist of the relock function inoperative after initial lock or door locks engaging with door open/ajar. Additionally, the double chirp horn alert which indicates door ajar does not operate when the key fob lock button is actuated. These may be due to the door ajar circuit missing from the Generic Electronic Module (GEM) to the Remote Anti-theft Personality (RAP) Module. ACTION Install missing Circuit 999. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the instrument panel fuse junction panel. Refer to the 1999 F-150/250 Workshop Manual, Page 419-10-3, Removal and Installation - Module GEM/CTM. 2. Disengage pin locking bar on C240 connector (GEM 16-way connector) and insert Circuit 999 (LB/W, jumper XL3Z-14A411-BA) into connector location Pin # 3 (Figure 1). Reinsert locking bar. 3. Remove left scuff plate and kick panel to access the C247F connector. 4. Route jumper wire along the -14401- harness to C247F connector at the -14A005- harness in left kick panel area. 5. Remove C247F connector (gray 16-way connector) from finger bracket and disconnect from mating connector. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Technical Service Bulletins > Customer Interest: > 99-21-3 > Oct > 99 > Autolock System - Functions Not Operating Properly > Page 61 6. Disengage and remove red locking spacer from C247F connector and insert Circuit 999 (LB/W, jumper XL3Z-14A411-BA) into connector location Pin # 3 (Figure 2). Reinsert red locking spacer. Spot tape jumper circuit along -14401-harness to the -14A005- harness. 7. Reconnect -14401- connector to -14A005- 16-way connector and reattach to finger bracket. 8. Reinstall left kick panel and scuff plate. 9. Reassemble instrument panel fuse junction panel and GEM per Workshop Manual, Page 419-10-3. 10. To functionally test repair, ensure either the driver/passenger door is open, press lock button on key fob twice, and listen for two horn chirps. 11. Connect New Generation Star (NGS) Tester to the vehicle and clear all codes. Then test RAP and GEM modules for any system failure induced during the repair procedure. PART NUMBER PART NAME XL3Z-14A411-BA Jumper Harness OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 992103A Repair Door Ajar Circuit 0.9 Hrs. DEALER CODING CONDITION BASIC PART NO. CODE 14A411 39 OASIS CODES: 112000, 203000, 203200, 205000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-21-3 > Oct > 99 > Autolock System - Functions Not Operating Properly General Module: All Technical Service Bulletins Autolock System - Functions Not Operating Properly Article No 99-21-3 10/18/99 AUTO-LOCK - AUTO-LOCK FUNCTIONS NOT OPERATING PROPERLY - VEHICLES BUILT FROM 6/3/1999 THROUGH 6/8/1999 FORD: 1999 F-150, F-250 LD ISSUE The Auto-Lock Functions may not be operating properly. This may consist of the relock function inoperative after initial lock or door locks engaging with door open/ajar. Additionally, the double chirp horn alert which indicates door ajar does not operate when the key fob lock button is actuated. These may be due to the door ajar circuit missing from the Generic Electronic Module (GEM) to the Remote Anti-theft Personality (RAP) Module. ACTION Install missing Circuit 999. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the instrument panel fuse junction panel. Refer to the 1999 F-150/250 Workshop Manual, Page 419-10-3, Removal and Installation - Module GEM/CTM. 2. Disengage pin locking bar on C240 connector (GEM 16-way connector) and insert Circuit 999 (LB/W, jumper XL3Z-14A411-BA) into connector location Pin # 3 (Figure 1). Reinsert locking bar. 3. Remove left scuff plate and kick panel to access the C247F connector. 4. Route jumper wire along the -14401- harness to C247F connector at the -14A005- harness in left kick panel area. 5. Remove C247F connector (gray 16-way connector) from finger bracket and disconnect from mating connector. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-21-3 > Oct > 99 > Autolock System - Functions Not Operating Properly > Page 67 6. Disengage and remove red locking spacer from C247F connector and insert Circuit 999 (LB/W, jumper XL3Z-14A411-BA) into connector location Pin # 3 (Figure 2). Reinsert red locking spacer. Spot tape jumper circuit along -14401-harness to the -14A005- harness. 7. Reconnect -14401- connector to -14A005- 16-way connector and reattach to finger bracket. 8. Reinstall left kick panel and scuff plate. 9. Reassemble instrument panel fuse junction panel and GEM per Workshop Manual, Page 419-10-3. 10. To functionally test repair, ensure either the driver/passenger door is open, press lock button on key fob twice, and listen for two horn chirps. 11. Connect New Generation Star (NGS) Tester to the vehicle and clear all codes. Then test RAP and GEM modules for any system failure induced during the repair procedure. PART NUMBER PART NAME XL3Z-14A411-BA Jumper Harness OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 992103A Repair Door Ajar Circuit 0.9 Hrs. DEALER CODING CONDITION BASIC PART NO. CODE 14A411 39 OASIS CODES: 112000, 203000, 203200, 205000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for General Module: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Four Wheel Drive Indicator Lamp: All Technical Service Bulletins Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for General Module: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 73 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for General Module: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 79 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions General Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 82 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 83 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 84 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 85 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 86 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 87 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 88 General Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 89 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 90 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 91 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 92 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 93 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 94 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 95 General Module: Connector Views Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 96 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 97 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 98 General Module: Electrical Diagrams Diagram 59-1 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 99 Diagram 59-2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 100 Diagram 59-3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 101 Diagram 59-4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Page 102 General Module: Description and Operation NOTE - Each vehicle has either a Generic Electronic Module (GEM) or Central Timer Module (CTM). The difference in functionality is defined in the GEM/CTM Feature Matrix. - The GEM/CTM inputs and outputs are designed to withstand continuous exposure to a short circuit to ground or battery voltage without being damaged. The multifunction modules consist of the following: - Remote Anti-Theft Personality (RAP) module - Central Timer Module (CTM) with diagnostic connector - Generic Electronic Module (GEM) GEM/CTM Feature Matrix Ignition Switch Positions The position of the ignition switch is very important to proper GEM/CTM operation. Often times, erratic or unexpected operation can be traced to problems on these GEM/CTM inputs. The following is a brief description of five ignition switch positions. When the ignition switch is in the RUN position, battery voltage should be present at the GEM/CTM RUN and RUN/ACC input terminals. When the ignition switch is in the ACC position, battery voltage should be present at the GEM/CTM RUN/ACC input terminal only. When the ignition switch is in the START position, battery voltage should be present at the GEM/CTM start/clutch depressed input. The GEM module does not have an OFF or LOCK switch state input. The GEM will assume the OFF or LOCK position when there are no RUN, ACC, or START signals present. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Page 103 General Module: Service and Repair Generic Electronic (GEM)/Central Timer (CTM) Module REMOVAL 1. Disconnect the battery ground cable. CAUTION Prior to removal of the module, it is necessary to upload module configuration information to New Generation STAR (NGS) Tester. This information needs to be downloaded into the new module once installed. - Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the steering column cover. 3. Remove the (A) bulkhead electrical connectors from the (B) instrument panel fuse junction panel. 4. Remove the (A) instrument panel fuse junction panel bolts and remove the (B) interior fuse junction panel nuts. 5. Disconnect the (A) Generic Electronic Module (GEM)/Central Timer Module (CTM) electrical connectors from the (B) GEM/CTM. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Page 104 6. Remove the screws and the GEM/CTM. INSTALLATION 1. To install, reverse the removal procedure. - Check for proper operation. CAUTION: Once the new module is installed, it is necessary to download the module configuration information from the New Generation STAR (NGS) Tester into the new module. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams Keyless Entry Module: Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Page 108 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams Keyless Entry Module: Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Page 113 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications Electronic Brake Control Module: Specifications TORQUE SPECIFICATIONS Rear Wheel Anti-Lock Control Module Screws ......................................................................................................................... 2-3 Nm (17-26 inch lbs.) 4-Wheel Anti-Lock Control Module Screws .............................................................................................................................. 4-5 Nm (36-44 inch lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Rear Antilock Brake (RABS) Module Electronic Brake Control Module: Locations Rear Antilock Brake (RABS) Module Instrument Panel View The Rear Anti-Lock Brake System Module is located behind right side of the instrument panel. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Rear Antilock Brake (RABS) Module > Page 120 Electronic Brake Control Module: Locations 4 Wheel Anti-Lock Brake System Module fm99ev326_151-007 The 4 Wheel Anti-Lock Brake System Module is located at the left side of the engine compartment. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Four Wheel Antilock Brakes Electronic Brake Control Module: Diagrams Four Wheel Antilock Brakes Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Four Wheel Antilock Brakes > Page 123 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) Electronic Brake Control Module: Service and Repair Four Wheel Anti-Lock Brake System (4WABS) Removal 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Disconnect the battery ground cable. 2. Disconnect the anti-lock brake control module electrical connectors. 3. Disconnect the pump motor electrical connector from the anti-lock brake control module. 4. Remove the anti-lock brake control module. 1 Remove the screws. 2 Remove the anti-lock brake control module. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 126 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 127 Electronic Brake Control Module: Service and Repair Rear Antilock Brake System (RABS) Removal 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Disconnect the battery ground cable. 2. Remove the instrument panel cluster panel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 3. Remove the anti-lock brake control module, 1 Disconnect the anti-lock brake control module electrical connector. 2 Remove the bolts. 3 Remove the anti-lock brake control module. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn, the strategy. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 135 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 136 Compressor Clutch Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 137 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Testing and Inspection Audible Warning Device Control Module: Testing and Inspection Refer to Instrument Panel/Testing and Inspection/Procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 150 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 151 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 152 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 158 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 159 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 160 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Module: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Speedometer Module: Customer Interest Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Module: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 169 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Module: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Speedometer Module: All Technical Service Bulletins Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Module: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 175 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > Page 176 Speedometer Module: Testing and Inspection Refer to Instrument Panel/Testing and Inspection/Procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Technical Service Bulletins > Battery Saver Relay - Malfunction Battery Discharge Protection Relay: Technical Service Bulletins Battery Saver Relay - Malfunction Article No. 00-19-2 09/18/00 ^ LAMP - COURTESY, GLOVE COMPARTMENT, UNDERHOOD, RUNNING BOARD LAMPS INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES ^ POWER WINDOWS - INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES ^ RADIO - INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES ^ REAR WIPER - INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES FORD: 1999-2000 EXPEDITION, F-150, F-250 LD LINCOLN: 1999-2000 NAVIGATOR This article is being republished in its entirety to update the part number. ISSUE A temporary loss of functions controlled by the battery saver relay may occur on some vehicles. These functions may be inoperative for a short period of time after the vehicle has sat unattended for at least 45 minutes. These functions are limited to courtesy and interior/demand lamps, glove compartment, underhood lamps and power windows. Running board lights, moonroof and the rear wiper may be affected on Expedition and Navigator. The radio may also be inoperative during this time on Navigator only. The loss of these features is temporary and can last from a few seconds up to 10-15 minutes. ACTION Replace the Battery Saver Relay (YL3Z-14N089-AA). Refer to the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) for location of this relay. NOTE PERMANENT LOSS OF ANY OF THESE FUNCTIONS SHOULD NOT BE ADDRESSED WITH THIS TSB. FUNCTIONS OTHER THAN THOSE EXPLICITLY MENTIONED ABOVE THAT ARE REPORTED TO BE INOPERATIVE SHOULD NOT BE ADDRESSED WITH THIS TSB. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-8-7 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION / DESCRIPTION / TIME Table Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Technical Service Bulletins > Battery Saver Relay - Malfunction > Page 182 DEALER CODING OASIS CODES: 10200, 204000, 201100, 201200, 202000, 20300, 205000, 207000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Technical Service Bulletins > Page 183 Battery Discharge Protection Relay: Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Technical Service Bulletins > Page 184 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Technical Service Bulletins > Page 185 Battery Discharge Protection Relay: Description and Operation The following components are under the control of the battery saver relay: ^ Delayed accessory relay. ^ Overhead interior lamp with map lamps. ^ Underhood lamp switch. ^ Glove box lamp switch. ^ Overhead interior lamp switch. ^ Interior lamp relay coil. The battery saver relay becomes active (relay coil is energized) when the GEM is in awake mode and is deactivated (relay coil is de-energized) in sleep mode. The battery saver will remain active until the ignition state is not ACC or RUN and 45 minutes have passed since last active input. At that time, the relay will be deactivated and power to the above circuits will terminate. Five minutes after the battery saver relay has become deactivated, the GEM will go into a lower power state known as sleep mode. In the sleep mode, the GEM will deactivate all outputs and will monitor select inputs. Logical characteristics of the GEM battery saver mode are as follows: Feature Inputs: ^ Sleep/Awake mode status. Feature Outputs: ^ Battery saver relay control (Open circuit in sleep mode, grounded when awake). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Technical Service Bulletins > Page 186 Battery Discharge Protection Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Technical Service Bulletins > Page 187 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations Courtesy Lamp Relay: Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations > Page 191 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations > Page 192 Courtesy Lamp Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations > Page 193 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Page 197 Daytime Running Lamp Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Page 198 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 202 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 203 Fog/Driving Lamp Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 204 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 211 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 212 Headlamp Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 213 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 217 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 218 Horn Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 219 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Description and Operation Interior Lighting Relay: Description and Operation The GEM and the CTM control the interior lamps and illuminated entry function with the interior lamp relay. The relay is activated by applying ground to the relay coil through GEM C267-15, and is deactivated by removing the ground signal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 226 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 227 Parking Lamp Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 228 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Regular Production Option Relay Block Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Regular Production Option Relay Block > Page 233 Trailer Lighting Relay: Locations Trailer Running Lamps Relay Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Regular Production Option Relay Block > Page 234 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Regular Production Option Relay Block > Page 235 Trailer Lighting Relay: Locations Trailer Tow Battery Charge Relay Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Regular Production Option Relay Block > Page 236 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Regular Production Option Relay Block > Page 237 Trailer Lighting Relay: Locations Trailer Tow Reversing Lamp Relay Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Regular Production Option Relay Block > Page 238 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 239 Trailer Lighting Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 240 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 245 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 249 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 255 Relay Box: Diagrams Central Junction Box Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 256 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 257 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 258 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 259 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Alternative Fuel Control Module > Component Information > Technical Service Bulletins > Bi-Fuel System - Compuvalve Replacement Alternative Fuel Control Module: Technical Service Bulletins Bi-Fuel System - Compuvalve Replacement Article No. 01-10-6 05/28/01 DRIVEABLITY - BI-FUEL - COMPUVALVE PRE-REPLACEMENT CHECK LIST - SERVICE TIPS FORD: 1996-2000 CONTOUR 1994-2001 F-150, F-250 LD 1995-2001 E-250, E-350 1999-2001 SUPER DUTY F SERIES ISSUE This article will be used as an aid in diagnosis to avoid unnecessary replacement of the compuvalve on bi-fuel vehicles after normal diagnosis has determined the compuvalve may be faulty. ACTION Complete the normal diagnostic methods and pinpoint tests. Should the conclusion be after normal diagnosis to replace the compuvalve, then follow the compuvalve Pre-Replacement Checklist (below) before replacing the compuvalve. SERVICE INFORMATION Glossary Of Terms ^ ALT - Alternate Fuel Mode ^ FAP - Fuel Absolute Pressure ^ HPS - High Pressure Solenoid ^ VCL - Vehicle Communications Link ^ AFCM - Alternate Fuel Control Module ^ WDS - Worldwide Diagnostic System ^ DTC - Diagnostic Trouble Code ^ MAP - Manifold Absolute Pressure ^ LPG - Liquid Propane Gas ^ EEC - Electronic Engine Control NOTE THE FOLLOWING IS A LIST OF KNOWN MIS-DIAGNOSIS OF THE COMPUVALVE REPLACEMENT ON BI-FUEL VEHICLES. 1. MAP line loose. 2. High FAP from vaporizer breakdown. 3. Incorrect interpretation of DTCs. 4. VCL replacement due to harness faults. 5. Misfire due to leaking 0-rings. 6. Compuvalve replaced without checking HPS circuit for correct resistance. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Alternative Fuel Control Module > Component Information > Technical Service Bulletins > Bi-Fuel System - Compuvalve Replacement > Page 266 7. Low FAP due to lockoff fault. 8. LPG fuel filter in backward. COMPUVALVE PRE-REPLACEMENT CHECKLIST 1. Check communication ability with EEC, AFCM/compuvalve and VCL and compuvalve. Follow the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual procedures for the appropriate vehicle. 2. Check MAP line. Follow normal diagnostic methods and visual checks. 3. Check harness and connection integrity. Follow normal diagnostic methods, basic circuit checks and harness connections. 4. Check current bi-fuel EEC calibration code. Refer to WDS. 5. Check fuel gauge with fuel selector switch in ALT position for fuel level. 6. Check power to compuvalve. Power to the compuvalve is indicated by the following fuel selector switch light status: On steady = OK, On then Off or Flashing (regular and irregular) indicated fault. 7. Check that the arrow on the LPG fuel filter is pointing in the direction of fuel flow. 8. Check base vehicle. Run vehicle in gas mode (e.g., borderline secondary ignition). Follow normal diagnostic methods. 9. Check other applicable TSBs and special service messages. 10. Verify ALT fuel switch status. Refer to Section 1 of the appropriate PC/ED Workshop Manual. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 490000, 602300, 603300, 608000, 609000, 611000, 623000, 690000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 275 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 276 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 277 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures Engine Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 283 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 284 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 289 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 290 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 291 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 99-4-3 > Mar > 99 > PCM - Reprogramming Out of Vehicle Engine Control Module: All Technical Service Bulletins PCM - Reprogramming Out of Vehicle Article No. 99-4-3 03/08/99 REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS) - OUT-OF-VEHICLE - EEC V VEHICLES ONLY FORD: 1994-97 THUNDERBIRD 1994-99 MUSTANG 1995-99 CROWN VICTORIA 1996-97 PROBE 1996-99 CONTOUR, ESCORT, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR 1995-99 CONTINENTAL, GRAND MARQUIS, TOWN CAR 1996-98 MARK VIII 1996-99 MYSTIQUE, SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1994-97 F SUPER DUTY, F-250 HD, F-350 1995-99 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-97 AEROSTAR 1996-99 EXPLORER, F-150, F-250 LD 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to update the affected vehicles and to include an Application Chart for the affected vehicles. ISSUE The Federal Environmental Protection Agency (EPA) has mandated that all aftermarket service centers shall be able to either reprogram Powertrain Control Modules (PCMs) or obtain reasonably priced, timely PCM programming services at dealerships. Ford has released an out-of-vehicle EEC V reprogramming cable to support this requirement. Also, PCMs are reprogrammable to update calibration levels or to reprogram a common hardware type to a new calibration in order to fill a service need without ordering a new PCM. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 99-4-3 > Mar > 99 > PCM - Reprogramming Out of Vehicle > Page 296 ACTION Refer to the Application Chart in this article to use the new 15- to 104-Pin Flash Cable to handle all necessary out-of-vehicle programming of EEC V modules in the vehicles listed. This may allow added flexibility in servicing aftermarket and fleet accounts as well as provide the ability to have modules updated to new calibrations through the Parts Department instead of ordering new parts. Currently, EEC V modules must be installed in a vehicle to reprogram a new calibration in the module. An aftermarket service center may bring a module to a dealership for a calibration update or may request an updated calibration be installed to a new service part. The EPA regulations require "reasonably priced, timely service" be provided by the dealer. The new 15- to 104-Pin Flash Cable works with the New Generation Star (NGS) Tester to provide the capability to reprogram a calibration on a PCM out of the vehicle. The 15- to 104-Pin Flash Cable connects between the NGS Tester and PCM 104-pin connector. The proper calibration must be downloaded to the Data Transfer Card through Service Bay Technical System (SBTS). Once the card is inserted into the NGS Tester and the cable is connected, follow the calibration download instructions displayed on the NGS screen. The 15- to 104-Pin Flash Cable (007-00587) can be ordered from Rotunda by calling 1-800-ROTUNDA. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-26-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 206000, 290000, 690000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures Engine Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 302 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 303 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 99-4-3 > Mar > 99 > PCM - Reprogramming Out of Vehicle Engine Control Module: All Technical Service Bulletins PCM - Reprogramming Out of Vehicle Article No. 99-4-3 03/08/99 REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS) - OUT-OF-VEHICLE - EEC V VEHICLES ONLY FORD: 1994-97 THUNDERBIRD 1994-99 MUSTANG 1995-99 CROWN VICTORIA 1996-97 PROBE 1996-99 CONTOUR, ESCORT, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR 1995-99 CONTINENTAL, GRAND MARQUIS, TOWN CAR 1996-98 MARK VIII 1996-99 MYSTIQUE, SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1994-97 F SUPER DUTY, F-250 HD, F-350 1995-99 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-97 AEROSTAR 1996-99 EXPLORER, F-150, F-250 LD 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to update the affected vehicles and to include an Application Chart for the affected vehicles. ISSUE The Federal Environmental Protection Agency (EPA) has mandated that all aftermarket service centers shall be able to either reprogram Powertrain Control Modules (PCMs) or obtain reasonably priced, timely PCM programming services at dealerships. Ford has released an out-of-vehicle EEC V reprogramming cable to support this requirement. Also, PCMs are reprogrammable to update calibration levels or to reprogram a common hardware type to a new calibration in order to fill a service need without ordering a new PCM. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 99-4-3 > Mar > 99 > PCM - Reprogramming Out of Vehicle > Page 308 ACTION Refer to the Application Chart in this article to use the new 15- to 104-Pin Flash Cable to handle all necessary out-of-vehicle programming of EEC V modules in the vehicles listed. This may allow added flexibility in servicing aftermarket and fleet accounts as well as provide the ability to have modules updated to new calibrations through the Parts Department instead of ordering new parts. Currently, EEC V modules must be installed in a vehicle to reprogram a new calibration in the module. An aftermarket service center may bring a module to a dealership for a calibration update or may request an updated calibration be installed to a new service part. The EPA regulations require "reasonably priced, timely service" be provided by the dealer. The new 15- to 104-Pin Flash Cable works with the New Generation Star (NGS) Tester to provide the capability to reprogram a calibration on a PCM out of the vehicle. The 15- to 104-Pin Flash Cable connects between the NGS Tester and PCM 104-pin connector. The proper calibration must be downloaded to the Data Transfer Card through Service Bay Technical System (SBTS). Once the card is inserted into the NGS Tester and the cable is connected, follow the calibration download instructions displayed on the NGS screen. The 15- to 104-Pin Flash Cable (007-00587) can be ordered from Rotunda by calling 1-800-ROTUNDA. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-26-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 206000, 290000, 690000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 309 Engine Control Module: Specifications Powertrain Control Module (PCM) Connector Screws 4.5 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 312 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 313 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 314 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 315 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 316 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 317 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 318 Engine Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 319 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 320 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 321 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 322 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 323 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 324 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 325 Engine Control Module: Connector Views Diagram 25-9 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 326 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 327 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 328 Engine Control Module: Description and Operation The powertrain control module needs the following inputs to calibrate the engine properly: ^ camshaft position. ^ engine rpm. ^ engine coolant temperature. ^ amount of engine detonation. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures Engine Control Module: Procedures Flash Electrically Erasable Programmable Read Only Memory is contained in an Integrated Circuit (IC) internally to the PCM. The EEPROM contains the vehicle strategy as well as any calibration information specific to the vehicle. The IC is reprogrammable and at times it may become necessary to reprogram or reflash the entire contents. This is usually due to either an after production strategy change or the Vehicle Identification (VID) area has been previously reprogrammed and has reached its limit. The VID block area can be tailored to accommodate various hardware changes made to the vehicle since production. The VID block is a section of memory within the IC which includes items such as octane adjust, fuel octane, fuel type, tire size and axle ratio. Programming a Replacement PCM A replacement PCM will display a label as shown. This indicates the need to retrieve VID data from the original PCM before removing from the vehicle. Refer to the flash VID block update procedure. After retrieving the VID data from the original PCM, install the new PCM. Select "Restore PCM config. (1)" to download the stored data. If the original PCM is nonfunctional, it becomes necessary to manually reprogram the VID block. The scan tool is used to perform this procedure and is done through the "PCM Programming" selection as described by the flash EEPROM procedure below. Follow screen instructions. Flash EEPROM Procedure When using the NGS to reprogram the entire IC contents, the NGS Flash kit will be used. The Service Bay Technical System (SBTS) is used to download the new strategy with calibration onto the NGS static RAM card (data transfer card). The card is part of the flash kit. Plug the NGS flash cable into the underdash OBD II connector. Follow the NGS screen instructions under "PCM Programming" or refer to the flash instruction manual provided in the kit. VID block information can also be viewed and changed during this procedure. Flash VID Block Procedure When using the NGS scan tool, the Ford Service Function (FSF) card is used along with the NGS flash cable. Plug the cable into the underdash OBD II connector. From the main menu, select "Service Bay Functions", "PCM-Powertrain Control Module" and then "Programmable Module Installation". The screen will now display two selections. The first is for old PCM information to be retrieved and stored within the NGS. The second is for restoring the new PCM with information which has been retrieved from the old PCM. Follow screen instructions or refer to the supplement instruction sheet included with the Ford Service Function card. Next, either a transfer of data from the old module to the new module or a manual update must be performed on the VID block. Follow screen instructions or refer to the supplement instruction sheet included with the Ford Service Function card. If the VID block has been reprogrammed previously, the scan tool will display a message. This message will indicate the need to reflash the entire IC. NOTE: If using a generic scan tool, follow the instruction manual provided by the tool manufacturer. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 331 Engine Control Module: Reset Procedure Purpose for Clearing Codes Resetting Keep Alive RAM will return PCM memory to its default setting. Adaptive learning contents such as idle and fuel trim are included. A PCM Reset is also part of a KAM Reset. After Keep Alive RAM has been reset, the vehicle may exhibit certain driveability concerns. It will be necessary to drive the vehicle to allow the PCM to relearn values for optimum driveability and performance. A Keep Alive Random Access Memory Reset is done as follows: During Key ON, Engine OFF with the scan tool, use the Reset Keep Alive Memory function. This is found in the Active Command Modes menu on the New Generation Star scan tool. If a generic scan tool is used, this function may not be supported. Refer to scan tool manufacturer's instruction manual. If an error message is received or the scan tool does not support this function, disconnecting the battery ground cable for a minimum of 5 minutes may be used as an alternative procedure. Powertrain Control Module (PCM/KAM Reset) All OBDII scan tools support the Powertrain Control Module (PCM) reset. The PCM Reset allows the scan tool to command the PCM to clear all emission-related diagnostic information. When resetting the PCM, a DTC P1000 will be stored in the PCM until all the OBD II system monitors or components have been tested to satisfy a drive cycle, without any other faults occurring. The following events occur when a PCM reset is performed: - Clears the number of Diagnostic Trouble Codes (DTCs). - Clears the DTCs. - Clears the freeze frame data. - Clears diagnostic monitoring test results. - Resets status of the OBD II system monitors. - Sets DTC P1000. NOTE: When using the New Generation Star (NGS) Scan Tool to perform a PCM reset, press the CLEAR button. This function is performed only after retrieval of continuous DTCs. New Generation Star and Generic Scan Tool Refer to the scan tool manufacturer's manual for specific instructions on how to perform PCM reset. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 332 Engine Control Module: Removal and Replacement REMOVAL 1. Remove the battery and battery tray. 2. Loosen the bolt and separate the PCM electrical connectors. 3. Remove the RH front door scuff plate. 4. Remove the RH cowl side trim panel. 5. Remove the PCM bracket clip. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 333 6. Remove the powertrain control module. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 337 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay Main Relay (Computer/Fuel System): Testing and Inspection PCM Power Relay Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay > Page 340 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Alternative Fuel Control Module > Component Information > Technical Service Bulletins > Bi-Fuel System - Compuvalve Replacement Alternative Fuel Control Module: Technical Service Bulletins Bi-Fuel System - Compuvalve Replacement Article No. 01-10-6 05/28/01 DRIVEABLITY - BI-FUEL - COMPUVALVE PRE-REPLACEMENT CHECK LIST - SERVICE TIPS FORD: 1996-2000 CONTOUR 1994-2001 F-150, F-250 LD 1995-2001 E-250, E-350 1999-2001 SUPER DUTY F SERIES ISSUE This article will be used as an aid in diagnosis to avoid unnecessary replacement of the compuvalve on bi-fuel vehicles after normal diagnosis has determined the compuvalve may be faulty. ACTION Complete the normal diagnostic methods and pinpoint tests. Should the conclusion be after normal diagnosis to replace the compuvalve, then follow the compuvalve Pre-Replacement Checklist (below) before replacing the compuvalve. SERVICE INFORMATION Glossary Of Terms ^ ALT - Alternate Fuel Mode ^ FAP - Fuel Absolute Pressure ^ HPS - High Pressure Solenoid ^ VCL - Vehicle Communications Link ^ AFCM - Alternate Fuel Control Module ^ WDS - Worldwide Diagnostic System ^ DTC - Diagnostic Trouble Code ^ MAP - Manifold Absolute Pressure ^ LPG - Liquid Propane Gas ^ EEC - Electronic Engine Control NOTE THE FOLLOWING IS A LIST OF KNOWN MIS-DIAGNOSIS OF THE COMPUVALVE REPLACEMENT ON BI-FUEL VEHICLES. 1. MAP line loose. 2. High FAP from vaporizer breakdown. 3. Incorrect interpretation of DTCs. 4. VCL replacement due to harness faults. 5. Misfire due to leaking 0-rings. 6. Compuvalve replaced without checking HPS circuit for correct resistance. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Alternative Fuel Control Module > Component Information > Technical Service Bulletins > Bi-Fuel System - Compuvalve Replacement > Page 346 7. Low FAP due to lockoff fault. 8. LPG fuel filter in backward. COMPUVALVE PRE-REPLACEMENT CHECKLIST 1. Check communication ability with EEC, AFCM/compuvalve and VCL and compuvalve. Follow the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual procedures for the appropriate vehicle. 2. Check MAP line. Follow normal diagnostic methods and visual checks. 3. Check harness and connection integrity. Follow normal diagnostic methods, basic circuit checks and harness connections. 4. Check current bi-fuel EEC calibration code. Refer to WDS. 5. Check fuel gauge with fuel selector switch in ALT position for fuel level. 6. Check power to compuvalve. Power to the compuvalve is indicated by the following fuel selector switch light status: On steady = OK, On then Off or Flashing (regular and irregular) indicated fault. 7. Check that the arrow on the LPG fuel filter is pointing in the direction of fuel flow. 8. Check base vehicle. Run vehicle in gas mode (e.g., borderline secondary ignition). Follow normal diagnostic methods. 9. Check other applicable TSBs and special service messages. 10. Verify ALT fuel switch status. Refer to Section 1 of the appropriate PC/ED Workshop Manual. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 490000, 602300, 603300, 608000, 609000, 611000, 623000, 690000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 350 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 351 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 354 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 355 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 356 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 357 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 358 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 359 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 360 Fuel Pump Relay: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 361 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 362 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 363 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 364 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 365 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 366 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 367 Fuel Pump Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 368 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 372 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay Main Relay (Computer/Fuel System): Testing and Inspection PCM Power Relay Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay > Page 375 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications Air Bag Control Module: Specifications Restraint Control Module ..................................................................................................................... ........................................................ 12 Nm (9 Lb-Ft) Grounding Screw (6 mm) ................................. ............................................................................................................................................ 12 Nm (9 Lb-Ft) Crash Sensor Grounding Screw (Weld Nut Repair Screw [8 mm]) ............................................................................................................. 12 Nm (9 Lb-Ft) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 380 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 381 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 382 Air Bag Control Module: Description and Operation The Restraints Control Module (RCM) performs the following functions: - signals the inflators to deploy the air bags in the event of a deployable crash, - monitors the air bag supplemental restraint system (SRS) for faults. - illuminates the air bag indicator if a fault is detected. - flashes the air bag indicator to indicate the Lamp Fault Code (LFC) detected. - communicates through the Data Link Connector (DLC) the current or historical Diagnostic Trouble Codes (DTCs). - signals the Generic Electronic Module (GEM) to activate a chime if the air bag indicator is not available and another SRS fault exists. NOTE: The safing sensor is internal to the RCM and is not serviced separately. The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the RUN position, the RCM will illuminate the air bag indicator located in the instrument cluster. When the ignition is cycled (turned off and then on), the air bag indicator will remain lit for six seconds and then go out. If an SRS fault exists, the air bag indicator will then flash the two-digit LFC. The air bag indicator will flash the LFC five times, then it will remain illuminated for the rest of the key cycle. The RCM will also communicate the current and historical DTCs through the DLC, using the New Generation Star (NGS) Tester. If the air bag indicator does not function, and the system detects a fault condition, the RCM will signal the GEM to activate an audible chime. The chime is a series of five sets of five tone bursts. If the chime is heard, the SRS and the air bag indicator require repair. LFCs are prioritized. If two or more faults occur at the same time, the fault having the highest priority will be displayed first. After that fault has been corrected, the next highest priority fault will be displayed. The RCM includes a backup power supply. This feature provides sufficient backup power to deploy the air bags in the event that the ignition circuit is damaged in a collision before the safing and air bag sensors determine that an air bag deployment is required. The backup power supply will deplete its stored energy approximately one minute after the battery ground cable is disconnected. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Programming A New Restraints Control Module (RCM) Air Bag Control Module: Service and Repair Programming A New Restraints Control Module (RCM) When installing a new Restraints Control Module (RCM) it must be programmed for the applicable vehicle configuration. Program the RCM using the following procedure. 1. Make sure that all of the SRS components are installed in the vehicle and the battery is connected. 2. Insert the FSF card in the NGS. 3. Connect the NGS to the Data Link Connector (DLC). 4. Key to RUN. 5. On the NGS select "Service Bay Functions". 6. Select "RCM-Restraints Control Module". 7. Select: - "Airbag Configuration 14" for vehicle with Passenger Airbag Deactivate Switch. - "Airbag Configuration 15" for vehicle without Passenger Airbag Deactivate Switch. 8. Wait for a process complete confirmation. 9. Key to OFF. 10. Prove out the system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Programming A New Restraints Control Module (RCM) > Page 385 Air Bag Control Module: Service and Repair Removal And Installation REMOVAL WARNING: To avoid accidental, deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: Repair is made by installing a new part only. If a new part does not correct the condition, in stall the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the lower center instrument panel finish panel. 1 Remove the two push pins. 2 Remove the panel. 3. Disconnect the Restraints Control Module (RCM) electrical connector. 1 Disengage the RCM electrical connector locking clip. 2 Disconnect the RCM electrical connector. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Programming A New Restraints Control Module (RCM) > Page 386 4. Remove the RCM and bracket assembly. 1 Remove the bracket retaining bolts. 2 Remove the RCM and bracket assembly. INSTALLATION 1. To install, reverse the removal procedure. WARNING: The tightening torque of the restraints control module (RCM) retaining bolts is critical for correct system operation. NOTE: Repair is made by installing a new part only. If a new part does not correct the condition, install the original part and perform the diagnostic procedure again. - Make sure to tighten the retaining bolts to specification. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Specifications Starter Relay: Specifications Starter Motor Solenoid Relay Switch Bolts ........................................................................................................................................ 7-9 N.m (61-79 Lb-In) Starter Motor Solenoid Relay Switch Terminal Nuts .......................................................................................................................... 5-7 N.m (44-62 Lb-In) Starter Motor Solenoid Relay Switch Cable Nuts .......................................................................................................................... 5-11.2 N.m (45-99 Lb-In) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Description and Operation > Automatic Transmission Starter Relay: Description and Operation Automatic Transmission The starter motor solenoid relay switch: - controls current to the starter solenoid. - is engaged by the ignition switch. - connects the battery to the starter motor. The digital TR sensor prevents starter motor engagement unless the transmission is in the NEUTRAL or PARK position. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Description and Operation > Automatic Transmission > Page 393 Starter Relay: Description and Operation Manual Transmission The starter motor solenoid relay switch: - controls current to the starter solenoid. - is engaged by the ignition switch. - connects the battery to the starter motor. The Clutch Pedal Position (CPP) switch prevents starter motor engagement unless the clutch pedal is pressed. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Description and Operation > Page 394 Starter Relay: Testing and Inspection Use the 73 Digital Multimeter to check for continuity between terminal 85 and all other terminals. If resistance is 5 ohms or less between terminal 85 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay terminals 86 and 30 directly to the positive battery terminal. Use the 73 Digital Multimeter set in the volts position to check for voltage at terminal 87A. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect a third jumper wire to terminal 85 and ground the jumper wire to a know good ground. Check for voltage at terminal 87. If battery voltage is not indicated, replace the relay. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Description and Operation > Page 395 Starter Relay: Service and Repair REMOVAL WARNING: WHEN CARRYING OUT MAINTENANCE ON THE STARTING SYSTEM BE AWARE THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE PROTECTIVE CAPS ARE IN PLACE WHEN MAINTENANCE IS COMPLETE. FAILURE TO FOLLOW THIS PROCEDURE MAY RESULT IN PERSONAL INJURY. 1. Disconnect the battery ground cable. 2. Remove the insulator. 3. Disconnect the starter motor solenoid relay switch wires and cables. - Disconnect the engine control sensor wiring terminal. - Remove the starter motor solenoid relay switch terminal nuts. - Remove the wiring. 4. Remove the starter motor solenoid relay switch. - Remove the bolts. - Remove the starter motor solenoid relay switch. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Description and Operation > Page 396 WARNING: WHEN CARRYING OUT MAINTENANCE ON THE STARTING SYSTEM BE AWARE THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE PROTECTIVE CAPS ARE IN PLACE WHEN MAINTENANCE IS COMPLETE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations Compressor/Pump Relay: Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 402 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 403 Compressor/Pump Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 404 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Locations Suspension Control Module: Locations An A-to-Z electrical components location list can be viewed at Vehicle/Locations. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Locations > Page 408 Suspension Control Module: Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts Control Module: Customer Interest Transfer Case - Inadvertent Shifts Article No. 01-14-1 07/23/01 ^ ELECTRICAL - ELECTRONIC SHIFT ON THE FLY (ESOF) TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS ^ TRANSMISSION - TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS VEHICLES EQUIPPED WITH ELECTRONIC SHIFT ON THE FLY (ESOF) ONLY FORD: 1999 F-250 LD 1999-2001 EXPEDITION, F-150 LINCOLN: 1999-2001 NAVIGATOR ISSUE Some vehicles may exhibit inadvertent 4X4 Hi or Low shift events, 4X4 and/or Low Range indicator flashing or solid or vehicle stuck in 4L after uncommanded shift. This may be caused by the 4X4 shift motor. ACTION Install a YL1Z-7G360-AA shift motor on vehicles built before 12/99. The YL1Z-7G360-AA shift motor with a grey contact plate cover replaces the prior design F75Z-7G360-AA motor with a blue contact plate cover. Grey cover shift motors contain improved sense plate material and shift motor terminal upgrade. For vehicles already equipped with the latest style shift motor, refer to the following Service Procedure for details. SERVICE PROCEDURE For overall description and operation of the Electronic Shift On The Fly (ESOF) Transfer Case refer to Section 308-07 of the appropriate model year Workshop Manual. NOTE ALL DIAGNOSIS BY SYMPTOM SECTIONS HEREIN ARE WRITTEN ASSUMING THAT VEHICLE IS ALREADY EQUIPPED WITH THE LATEST STYLE SHIFT MOTOR. ALWAYS REPLACE SHIFT MOTOR AS A FIRST STEP IF CURRENT MOTOR IS PRIOR LEVEL WITH BLUE COVER. NOTE TO RESET THE GEM'S 4X4 MONITORING SOFTWARE, USE CLEAR DTC COMMAND IN THE NGS OR WOS TESTER (EVEN IF NO DTC'S ARE AVAILABLE) AND CYCLE IGNITION KEY ON-OFF-ON. RECORD ANY CONTINUOUS MEMORY CODES PRIOR TO CLEARING DTCs. NOTE AN UNCOMMANDED 4H OR 4L SHIFT DUE TO FALSE SHIFT MOTOR CONTACT PLATE SIGNAL MAY OR MAY NOT BE ACCOMPANIED BY SHIFT MOTOR DTC'S P1838, P1846, P1850, P1854, P1858, P1866, AND/OR P1867 STORED IN THE GEM DEPENDING ON WHETHER THE IGNITION KEY WAS CYCLED AFTER THE EVENT. NOTE CONTACT PLATE PIDS READ OPPOSITE OF 1999 OR EARLIER WORKSHOP MANUALS WHEN VIEWED WITH NGS RED CARD VERSIONS 15.0 OR LATER. THIS TSB CONTENT REFLECTS USING NGS VERSION 18.0. UNCOMMANDED SHIFT TO 4L 1. Parking Maneuvers/Gear Lever Transitions: Symptoms noted during a lower speed uncommanded shift to 4L event include: ^ Front end binding or hopping while turning ^ Bind feel in drivetrain when backing up and/or turning Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 419 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 420 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts Control Module: All Technical Service Bulletins Transfer Case - Inadvertent Shifts Article No. 01-14-1 07/23/01 ^ ELECTRICAL - ELECTRONIC SHIFT ON THE FLY (ESOF) TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS ^ TRANSMISSION - TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS VEHICLES EQUIPPED WITH ELECTRONIC SHIFT ON THE FLY (ESOF) ONLY FORD: 1999 F-250 LD 1999-2001 EXPEDITION, F-150 LINCOLN: 1999-2001 NAVIGATOR ISSUE Some vehicles may exhibit inadvertent 4X4 Hi or Low shift events, 4X4 and/or Low Range indicator flashing or solid or vehicle stuck in 4L after uncommanded shift. This may be caused by the 4X4 shift motor. ACTION Install a YL1Z-7G360-AA shift motor on vehicles built before 12/99. The YL1Z-7G360-AA shift motor with a grey contact plate cover replaces the prior design F75Z-7G360-AA motor with a blue contact plate cover. Grey cover shift motors contain improved sense plate material and shift motor terminal upgrade. For vehicles already equipped with the latest style shift motor, refer to the following Service Procedure for details. SERVICE PROCEDURE For overall description and operation of the Electronic Shift On The Fly (ESOF) Transfer Case refer to Section 308-07 of the appropriate model year Workshop Manual. NOTE ALL DIAGNOSIS BY SYMPTOM SECTIONS HEREIN ARE WRITTEN ASSUMING THAT VEHICLE IS ALREADY EQUIPPED WITH THE LATEST STYLE SHIFT MOTOR. ALWAYS REPLACE SHIFT MOTOR AS A FIRST STEP IF CURRENT MOTOR IS PRIOR LEVEL WITH BLUE COVER. NOTE TO RESET THE GEM'S 4X4 MONITORING SOFTWARE, USE CLEAR DTC COMMAND IN THE NGS OR WOS TESTER (EVEN IF NO DTC'S ARE AVAILABLE) AND CYCLE IGNITION KEY ON-OFF-ON. RECORD ANY CONTINUOUS MEMORY CODES PRIOR TO CLEARING DTCs. NOTE AN UNCOMMANDED 4H OR 4L SHIFT DUE TO FALSE SHIFT MOTOR CONTACT PLATE SIGNAL MAY OR MAY NOT BE ACCOMPANIED BY SHIFT MOTOR DTC'S P1838, P1846, P1850, P1854, P1858, P1866, AND/OR P1867 STORED IN THE GEM DEPENDING ON WHETHER THE IGNITION KEY WAS CYCLED AFTER THE EVENT. NOTE CONTACT PLATE PIDS READ OPPOSITE OF 1999 OR EARLIER WORKSHOP MANUALS WHEN VIEWED WITH NGS RED CARD VERSIONS 15.0 OR LATER. THIS TSB CONTENT REFLECTS USING NGS VERSION 18.0. UNCOMMANDED SHIFT TO 4L 1. Parking Maneuvers/Gear Lever Transitions: Symptoms noted during a lower speed uncommanded shift to 4L event include: ^ Front end binding or hopping while turning ^ Bind feel in drivetrain when backing up and/or turning Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 426 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 427 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Four Wheel Drive Indicator Lamp: All Technical Service Bulletins Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 433 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 439 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 440 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Shift on the Fly Relay Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Shift on the Fly Relay > Page 445 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Page 446 Four Wheel Drive Selector Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Page 447 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations Power Window Relay: Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Page 452 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Page 453 Power Window Relay: Description and Operation The GEM controls manual down and OTD window movement with the one touch down relay. The relay is activated by applying ground directly to one side of the down window relay coil, and is deactivated by removing the ground signal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Page 454 Power Window Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Page 455 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations Windshield Washer Relay: Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 460 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 461 Windshield Washer Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 462 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay Wiper Relay: Locations Wiper High/Low Relay Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 467 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 468 Wiper Relay: Locations Wiper Run/Park Relay Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 469 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 470 Wiper Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 471 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Revised Article No. 01-21-6 10/29/01 ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE MERCURY HOOD LAMP SWITCH FORD: 1987-1995 TAURUS 1988-1991 CROWN VICTORIA 1989 THUNDERBIRD 1989-1996 MUSTANG 1994-1996 THUNDERBIRD 1990 BRONCO II 1990-1996 RANGER 1991-1996 BRONCO 1994-2001 EXPLORER 1997-2001 F-150 2000-2001 EXCURSION 2002 EXPEDITION LINCOLN: 1989-1994 CONTINENTAL 1990-1992 MARK VII 1990-1996 TOWN CAR 1993-1995 MARK VIII 2002 NAVIGATOR MERCURY: 1987-1995 SABLE 1988-1991 GRAND MARQUIS 1989 COUGAR 1994-1996 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is to provide information on replacement hood lamp switches. The 27 degree Mercury style hood switches will no longer be available. Replacement 27 degree Mechanical switches will be available as a service replacement. ACTION For vehicles requiring hood lamp switch replacement, replace the 27 degree Mercury switch with new 27 degree Mechanical switch. Replace hood lamp switch per the appropriate model year Workshop Manual as needed. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised > Page 479 OASIS CODES: 201000, 201200 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Left Power Door Lock Switch Power Door Lock Switch: Diagrams Left Power Door Lock Switch Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Left Power Door Lock Switch > Page 484 Power Door Lock Switch: Diagrams Right Front Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > With Remote Anti-Theft Personality Power Door Lock Switch: Testing and Inspection With Remote Anti-Theft Personality Left Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > With Remote Anti-Theft Personality > Page 487 Schematic Right Component Testing Procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > With Remote Anti-Theft Personality > Page 488 Terminals Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > With Remote Anti-Theft Personality > Page 489 Power Door Lock Switch: Testing and Inspection Without Remote Anti-Theft Personality Left Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > With Remote Anti-Theft Personality > Page 490 Schematic Right Component Testing Procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > With Remote Anti-Theft Personality > Page 491 Terminals Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Left Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Left > Page 496 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Left > Page 497 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Component Testing Procedure Power Mirror Switch: Testing and Inspection Component Testing Procedure Component Testing Procedure (part 1 Of 2) Component Testing Procedure (part 2 Of 2) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Component Testing Procedure > Page 500 Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Component Testing Procedure > Page 501 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Component Testing Procedure > Page 502 Power Mirror Switch: Testing and Inspection Component Tests OUTSIDE REAR VIEW MIRROR CONTROL SWITCH Measure the resistance between the following terminals while pressing the switch in the requested directions: If the resistance is less than 5 ohms in each direction, return to the originating pinpoint test otherwise, replace the switch. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 506 Power Seat Switch: Testing and Inspection Component Testing Procedure Component Testing Procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 507 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 508 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 509 Power Seat Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the front seat back recliner handle. 1 Remove the screw. 2 Remove the front seat back recliner handle. 3. Remove the front seat lumbar support knob. 4. Remove the front seat track side shield. 1 Remove the screws. 2 Remove the pin-type retainer. 3 Remove the front seat track side shield. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 510 5. Disconnect the seat regulator control switch from the front seat track side shield. 1 Remove the screws. 2 Disconnect the seat regulator control switch. 6. Disconnect the seat regulator control switch electrical connector and remove the seat regulator control switch. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 511 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 6 km (10 mi) or more to relearn the strategy. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 516 Brake Fluid Level Sensor/Switch: Description and Operation The brake master cylinder fluid level warning switch is an integral part of the brake master cylinder reservoir. It consists of a float containing a magnet and a reed switch mounted in the bottom of the brake master cylinder reservoir. When the brake fluid in the brake master cylinder reservoir gets to a predetermined level, the floating magnet actuates the reed switch, causing the red brake warning indicator to illuminate. Loss of brake fluid from either the primary (front) hydraulic circuit or secondary (rear) hydraulic circuit will cause the warning indicator to activate. If the brake fluid level warning switch is inoperative, the brake master cylinder reservoir must be installed new. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Specifications Parking Brake Release Switch: Specifications TORQUE SPECIFICATIONS Parking Brake Release Handle Screws ................................................................................................................................. 2.7-3.7 Nm (25-33 inch lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Rear Anti-Lock Brakes Wheel Speed Sensor: Specifications Rear Anti-Lock Brake Sensor Rear Anti-Lock Brake Sensor Indicator Clearance 0.005-0.045 in Rear Anti-Lock Brake Sensor Bolt 24-29 ft.lb Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Rear Anti-Lock Brakes > Page 524 Wheel Speed Sensor: Specifications Front Anti-Lock Brake Sensor Bolt 63-80 in.lb Rear Anti-Lock Brake Sensor Bolt 20 ft.lb Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Rear Wheel Speed Sensor: Service and Repair Rear Removal 1. Raise and support vehicle. 2. NOTE: Clean off dirt and debris that may have collected around the rear anti-lock brake sensor before removal. Remove the rear anti-lock brake sensor. 1 Disconnect the rear anti-lock brake sensor electrical connector. 2 Remove the bolt. 3 Remove the rear anti-lock brake sensor. Installation 1. NOTE: Thoroughly clean the mounting surface. NOTE: Inspect the anti-lock brake sensor 0-ring for damage; lightly lubricate the 0-ring with High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C92-A. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Rear > Page 527 Wheel Speed Sensor: Service and Repair 4 Wheel Antilock Brake System Front Removal 1. Disconnect the front brake anti-lock sensor electrical connector. 2. Remove the front disc brake rotor shield. 3. Remove the (A) front brake anti-lock sensor bolts and the (B) front brake anti-lock sensor. Installation 1. To install, reverse the removal procedure. Rear Removal 1. Raise and support vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Rear > Page 528 2. NOTE: Clean off dirt and debris that may have collected around the rear anti-lock brake sensor before removal. Remove the rear anti-lock brake sensor. 1 Disconnect the rear anti-lock brake sensor electrical connector. 2 Remove the bolt. 3 Remove the rear anti-lock brake sensor. Installation 1. NOTE: Thoroughly clean the mounting surface. NOTE: Inspect the anti-lock brake sensor O-ring for damage; lightly lubricate the O-ring with High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor (ECT) 16-24 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications Engine Temperature Sensor: Specifications Cylinder Head Temperature (CHT) Sensor 6.9-13.5 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications > Page 537 Engine Temperature Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Remove the Cylinder Head Temperature (CHT) sensor. 1 Disconnect the connector. 2 Remove the CHT sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications Temperature Sensor (Gauge): Specifications Temperature Sender 20 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications > Page 541 Temperature Sensor (Gauge): Service and Repair Removal All Engines 1. Partially drain the cooling system. 4.6L Engines 2. Disconnect the connector and remove the water temperature indicator sender unit. 5.4L Engines 3. Disconnect the connector and remove the water temperature indicator sender unit. Installation 1. To install, reverse the removal procedure. - Fill the cooling system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 551 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 552 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 553 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 554 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 555 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 556 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 557 Attachment III - Technical Information Table of Contents Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 558 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 559 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 560 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 561 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 562 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 563 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 564 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 565 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 566 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 567 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 568 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 569 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 570 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 571 ERROR: stackunderflow OFFENDING COMMAND: begin STACK: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): Recalls Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 576 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Brake Switch (Cruise Control): Recalls Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 586 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 587 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 588 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 589 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 590 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 591 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 592 Attachment III - Technical Information Table of Contents Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 593 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 594 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 595 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 596 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 597 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 598 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 599 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 600 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 601 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 602 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 603 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 604 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 605 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 606 ERROR: stackunderflow OFFENDING COMMAND: begin STACK: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): All Technical Service Bulletins Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 611 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Brake Switch (Cruise Control): All Technical Service Bulletins Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Page 616 Brake Switch (Cruise Control): Specifications Deactivator Switch ............................................................................................................................... ........................................... 15-20 N.m (11-15 Lb-Ft) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Page 617 Brake Switch (Cruise Control): Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the deactivator switch electrical connector. 3. Remove the deactivator switch. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. - After the deactivator switch is installed, it is necessary to bleed the brake system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Recalls for Cruise Control Switch: > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Cruise Control Switch: Recalls Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Switch: > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Cruise Control Switch: All Technical Service Bulletins Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 631 Cruise Control Switch: Service and Repair REMOVAL 1. Remove the driver side air bag module. 2. Remove the speed control actuator switch. 1 Release the four (A) speed control actuator switch clips and remove the (B) speed control actuator switch. 2 Disconnect the speed control actuator switch electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Sender: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference Oil Pressure Sender: Customer Interest Oil Pressure Sending Unit - Drip Shield Interference Article No. 01-4-2 3/05/01 ENGINE - 5.4L - OIL SENDING UNIT INTERFERENCE FIT AT ENGINE OIL DRIP SHIELD - 4X4 VEHICLES EQUIPPED WITH 5.4L ENGINE ONLY FORD: 1998 F-250 LD 1998-2001 EXPEDITION, F-150 1999-2001 SUPER DUTY F SERIES LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit the engine oil sending unit contacting the oil drip shield attached to the front axle. This may be caused by tight tolerances between the engine oil sending unit and the engine oil drip shield. This may cause a malfunction of the engine oil sending unit. ACTION If the engine oil sending unit needs to be replaced due to contact with the drip shield, modify the engine oil drip shield as shown. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE IF THE ENGINE OIL SENDING UNIT NEEDS TO BE REPLACED IN SERVICE, MODIFY THE ENGINE OIL DRIP SHIELD BEFORE INSTALLING THE NEW ENGINE OIL SENDING UNIT. 1. Remove oil drip shield from front axle. This shield is attached to the front axle by three (3) bolts. 2. Modify shield as shown (Figure 1). Remove excess material from shield. Remove any sharp edges or burrs upon finishing cutting operation. 3. Reinstall engine oil drip shield. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Sender: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference > Page 641 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODE OASIS CODES: 401000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Sender: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference Oil Pressure Sender: All Technical Service Bulletins Oil Pressure Sending Unit - Drip Shield Interference Article No. 01-4-2 3/05/01 ENGINE - 5.4L - OIL SENDING UNIT INTERFERENCE FIT AT ENGINE OIL DRIP SHIELD - 4X4 VEHICLES EQUIPPED WITH 5.4L ENGINE ONLY FORD: 1998 F-250 LD 1998-2001 EXPEDITION, F-150 1999-2001 SUPER DUTY F SERIES LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit the engine oil sending unit contacting the oil drip shield attached to the front axle. This may be caused by tight tolerances between the engine oil sending unit and the engine oil drip shield. This may cause a malfunction of the engine oil sending unit. ACTION If the engine oil sending unit needs to be replaced due to contact with the drip shield, modify the engine oil drip shield as shown. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE IF THE ENGINE OIL SENDING UNIT NEEDS TO BE REPLACED IN SERVICE, MODIFY THE ENGINE OIL DRIP SHIELD BEFORE INSTALLING THE NEW ENGINE OIL SENDING UNIT. 1. Remove oil drip shield from front axle. This shield is attached to the front axle by three (3) bolts. 2. Modify shield as shown (Figure 1). Remove excess material from shield. Remove any sharp edges or burrs upon finishing cutting operation. 3. Reinstall engine oil drip shield. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Sender: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference > Page 647 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODE OASIS CODES: 401000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Technical Service Bulletins > Page 648 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Mechanical Specifications Refrigerant Pressure Sensor / Switch: Mechanical Specifications A/C Cycling Switch .............................................................................................................................. ......................................... 1.4-3.8 N.m (12-33 Lb-In) Pressure Cut Off Switch ................................... .......................................................................................................................................... 10 N.m (89 Lb-In) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Mechanical Specifications > Page 654 Refrigerant Pressure Sensor / Switch: Pressure, Vacuum and Temperature Specifications A/C Cycling Switch Close ................................................................................................................................................... ..................................... 324 kPa (47 psi) Maximum Open .................................................................. ....................................................................................................................... 152 kPa (22 psi) Minimum Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Cutoff Switch Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Cutoff Switch Typical Air Conditioning Pressure Sensor The A/C pressure cut-off switch is used to interrupt the A/C compressor operation in the event of high system discharge pressures. - The A/C pressure cut-off switch is mounted on a Schrader valve-type fitting on the high pressure side of the A/C manifold and tube. - A valve depressor, located inside the threaded end of the A/C pressure cut-off switch, presses on the Schrader valve stem. - This allows the A/C pressure cut-off switch to monitor the compressor discharge pressure. - When the compressor discharge pressure rises to approximately 2,999-3,276 kPa (435-475 psi), the switch contacts open, disengaging the A/C compressor. - When the pressure drops to approximately 1,585-2,000 kPa (230-290 psi), the contacts close to allow operation of the A/C compressor. - It is not necessary to discharge the refrigerant system to remove the A/C pressure cut-off switch. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Cutoff Switch > Page 657 Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Switch A/C Cycling Switch The A/C cycling switch is mounted on a Schrader valve-type fitting on the top of the suction accumulator/drier. - A valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the Schrader valve stem. - This allows the suction pressure inside the suction accumulator/drier to control the operation of the A/C cycling switch. - The electrical switch contacts open when the suction pressure drops to 151-173 kPa (22-25 psi). - The contacts close when the suction pressure rises to 268-324 kPa (39-47 psi). - When the A/C cycling switch contacts close, the A/C clutch field coil is energized. - When the A/C cycling switch contacts open, the A/C clutch field coil is deenergized and compressor operation stops. - The A/C cycling switch will control the A/C evaporator core pressure at a point where the plate/fin surface temperature will be maintained slightly above freezing. - This prevents icing of the A/C evaporator core and blockage of airflow. - It is not necessary to discharge the refrigerant system to remove the A/C cycling switch. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch Refrigerant Pressure Sensor / Switch: Service and Repair A/C Cycling Switch REMOVAL 1. Disconnect the A/C cycling pressure switch electrical connector. 2. Remove the A/C cycling switch from the top of the suction accumulator/drier. INSTALLATION 1. Follow the removal procedure in reverse order. - Lubricate the O-ring with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch > Page 660 Refrigerant Pressure Sensor / Switch: Service and Repair A/C Pressure Cut-Off Switch REMOVAL 1. Disconnect the A/C pressure cut-off switch electrical connector. 2. Remove the A/C pressure cut-off switch. INSTALLATION 1. Follow the removal procedure in reverse order. - Lubricate the O-ring seal with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Description and Operation Dimmer Switch: Description and Operation The panel dimmer switch is integrated into the headlamp switch and controls the interior lamps by activating the interior lamp relay. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Specifications Ambient Light Sensor: Specifications Light Sensor Amplifier Screws ................................................................................................................................................ 2.1-2.9 Nm (18.5-25.6 in lbs) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair Brake Light Switch: Service and Repair REMOVAL 1. Disconnect the Brake Pedal Position (BPP) switch connector. 2. Remove the BPP switch. 1 Remove the self-locking pin. 2 Remove the spacer. 3 Remove the BPP switch. INSTALLATION 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 00-9-6 > May > 00 > Windshield Wipers - Operate While Switch is OFF Combination Switch: Customer Interest Windshield Wipers - Operate While Switch is OFF Article No. 00-9-6 DATE 5/1/00 TITLE WINDSHIELD WIPERS - FRONT WIPERS OPERATE WHILE SWITCH IS IN "OFF" POSITION FORD: 1999 TAURUS 1999-2000 MUSTANG, EXPLORER, F-150, F-250 LD, RANGER, WINDSTAR 2000 EXCURSION MERCURY: 1999 SABLE 1999-2000 MOUNTAINEER This TSB is being republished in its entirety to revise the vehicles affected and to update the Service Procedure. This TSB applies to the following vehicles only: Explorer, Mountaineer and Ranger 4X2 Without Power Windows built through 9/12/1999 Excursion built through 8/25/1999 F-150/250, Mustang, Windstar, Taurus/Sable built through 8/16/1999 ISSUE The front windshield wipers may operate while the multifunction switch is in the OFF position on some vehicles. This may be caused by a resistance drift in the multifunction switch or a partially plugged-in connector. ACTION If the uncommanded wiper operation condition is present and all wiper related connectors are fully seated, install a revised multifunction switch. Refer to the following Service Procedure and the Multifunction Switch Application Chart for the applicable switch. SERVICE PROCEDURE NOTE: DO NOT ATTEMPT TO REPAIR THE VEHICLE BY REPLACING THE GENERIC ELECTRONIC MODULE (GEM) OR THE WIPER CONTROL MODULE. NOTE: MAKE SURE THAT ALL CONNECTIONS ARE FULLY SEATED TO THE GEM, CENTER INSTRUMENT PANEL COMPONENTS, FRONT WIPER MOTOR AND MULTIFUNCTION SWITCH DURING INSTALLATION. CHECK THE MULTIFUNCTION SWITCH CONNECTION CLOSELY FOR LOOSE CONNECTIONS, TERMINALS, AND TERMINAL PUSH OUTS. DO NOT ATTEMPT A CONTINUITY CHECK OR PROBE THE CIRCUITS OF THE WIRE HARNESS. If non-wiper related symptoms are present, perform diagnostics per the appropriate Workshop Manual. If the uncommanded wiper operation condition is present and no other symptoms apply to the vehicle being serviced, install a revised multifunction switch. Refer to the Multifunction Switch Application Chart for the applicable switch. NOTE: MAKE SURE THAT ALL CONNECTIONS ARE FULLY SEATED DURING INSTALLATION. DO NOT ATTEMPT TO REPAIR THE VEHICLE BY REPLACING THE GEM OR THE WIPER CONTROL MODULE. Using Worldwide Diagnostic System (WDS), New Generation Star (NGS) Jester or Service Bay Diagnostic System (SBDS), run GEM or CTM. Retrieve and clear continuous Diagnostic Trouble Codes (DTCs) and run On-Demand Self-Test to make sure that no valid DTCs are set. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 00-9-6 > May > 00 > Windshield Wipers - Operate While Switch is OFF > Page 683 MALFUNCTION SWITCH APPLICATION PARTS SUPERSEDES: 99-24-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 202000, 203000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 00-9-6 > May > 00 > Windshield Wipers - Operate While Switch is OFF Combination Switch: All Technical Service Bulletins Windshield Wipers - Operate While Switch is OFF Article No. 00-9-6 DATE 5/1/00 TITLE WINDSHIELD WIPERS - FRONT WIPERS OPERATE WHILE SWITCH IS IN "OFF" POSITION FORD: 1999 TAURUS 1999-2000 MUSTANG, EXPLORER, F-150, F-250 LD, RANGER, WINDSTAR 2000 EXCURSION MERCURY: 1999 SABLE 1999-2000 MOUNTAINEER This TSB is being republished in its entirety to revise the vehicles affected and to update the Service Procedure. This TSB applies to the following vehicles only: Explorer, Mountaineer and Ranger 4X2 Without Power Windows built through 9/12/1999 Excursion built through 8/25/1999 F-150/250, Mustang, Windstar, Taurus/Sable built through 8/16/1999 ISSUE The front windshield wipers may operate while the multifunction switch is in the OFF position on some vehicles. This may be caused by a resistance drift in the multifunction switch or a partially plugged-in connector. ACTION If the uncommanded wiper operation condition is present and all wiper related connectors are fully seated, install a revised multifunction switch. Refer to the following Service Procedure and the Multifunction Switch Application Chart for the applicable switch. SERVICE PROCEDURE NOTE: DO NOT ATTEMPT TO REPAIR THE VEHICLE BY REPLACING THE GENERIC ELECTRONIC MODULE (GEM) OR THE WIPER CONTROL MODULE. NOTE: MAKE SURE THAT ALL CONNECTIONS ARE FULLY SEATED TO THE GEM, CENTER INSTRUMENT PANEL COMPONENTS, FRONT WIPER MOTOR AND MULTIFUNCTION SWITCH DURING INSTALLATION. CHECK THE MULTIFUNCTION SWITCH CONNECTION CLOSELY FOR LOOSE CONNECTIONS, TERMINALS, AND TERMINAL PUSH OUTS. DO NOT ATTEMPT A CONTINUITY CHECK OR PROBE THE CIRCUITS OF THE WIRE HARNESS. If non-wiper related symptoms are present, perform diagnostics per the appropriate Workshop Manual. If the uncommanded wiper operation condition is present and no other symptoms apply to the vehicle being serviced, install a revised multifunction switch. Refer to the Multifunction Switch Application Chart for the applicable switch. NOTE: MAKE SURE THAT ALL CONNECTIONS ARE FULLY SEATED DURING INSTALLATION. DO NOT ATTEMPT TO REPAIR THE VEHICLE BY REPLACING THE GEM OR THE WIPER CONTROL MODULE. Using Worldwide Diagnostic System (WDS), New Generation Star (NGS) Jester or Service Bay Diagnostic System (SBDS), run GEM or CTM. Retrieve and clear continuous Diagnostic Trouble Codes (DTCs) and run On-Demand Self-Test to make sure that no valid DTCs are set. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 00-9-6 > May > 00 > Windshield Wipers - Operate While Switch is OFF > Page 689 MALFUNCTION SWITCH APPLICATION PARTS SUPERSEDES: 99-24-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 202000, 203000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Dome Lamp Switch > Component Information > Service and Repair Dome Lamp Switch: Service and Repair Switch - Interior Lamp Removal 1. Remove the front door trim panel. Please refer to Body and Frame/Doors, Hood and Trunk/Door/Door Panel/Service and Repair/ See: Body and Frame/Doors, Hood and Trunk/Doors 2. Remove the interior lamp switch. a. Disconnect the interior lamp switch electrical connector. b. Rotate interior lamp switch counterclockwise and remove. Installation 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Service and Repair Fog/Driving Lamp Switch: Service and Repair REMOVAL AND INSTALLATION The fog lamp switch is integral to the headlamp switch. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions Hazard Warning Switch: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 701 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 702 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 703 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 704 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 705 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 706 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 707 Hazard Warning Switch: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 708 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 709 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 710 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 711 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 712 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 713 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 714 Hazard Warning Switch: Electrical Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 715 Hazard Warning Switch: Description and Operation The integrated multifunction switch is mounted to the LH side of the steering column and controls the turn signal, headlamp dimmer/flash-to-pass, windshield wiper/washer and hazard warning. The ignition switch is mounted below the steering column and is activated using the ignition key and rotating the key lock cylinder on the steering column. If equipped with manual transmission, the key release lever prevents rotation of the ignition cylinder to LOCK or ACC positions unless the lever is depressed. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis Hazard Warning Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 718 Hazard Warning Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 719 Hazard Warning Switch: Diagnostic Trouble Code Descriptions GEM/CTM Active Command Index Part 1 Of 2 Part 2 Of 2 GEM/CTM Diagnostic Trouble Code (DTC) Index Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 720 Part 1 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 721 Part 2 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 722 Part 3 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 723 Part 4 Of 4 GEM/CTM Parameter Identification (PID) Index Part 1 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 724 Part 2 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 725 Part 3 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 726 Hazard Warning Switch: Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 727 Hazard Warning Switch: Testing and Inspection Flow of Diagnosis 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Initial Inspection and Diagnostic Overview Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 728 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures GEM/CTM Active Command Index Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 729 Part 1 Of 2 Part 2 Of 2 GEM/CTM Diagnostic Trouble Code (DTC) Index Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 730 Part 1 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 731 Part 2 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 732 Part 3 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 733 Part 4 Of 4 GEM/CTM Parameter Identification (PID) Index Part 1 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 734 Part 2 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 735 Part 3 Of 3 Symptom Related Diagnostic Procedures Part 1 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 736 Part 2 Of 2 Test A: No Communication With the GEM or CTM Test A1 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 737 Test A2 - A3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 738 Test A4 - A5 Test B: Unable to Enter Self-Test Test B1 Test C: Ignition Switch Is Inoperative Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 739 Test C1 Test D: No Power In ACC Test D1 Test E: No Power In Run Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 740 Test E1 Test E1 - E2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 741 Test F: No Power In Start Test F1 - F2 Component Tests and General Diagnostics Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 742 Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 743 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Page 744 Hazard Warning Switch: Service and Repair MULTIFUNCTION SWITCH Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1. Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2. Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder 3. Twist the tilt wheel handle and shank and remove. 4. NOTE: Move gear selector to lowest position to access steering column opening cover. Release the four clips and remove the steering column opening cover. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Page 745 5. Remove the upper and lower steering column shrouds. 1. Remove the three screws. 2. Remove the lower steering column shroud. 3. Remove the upper steering column shroud. 6. Remove the mult1 function switch. 1. Remove the two screws. 2. Disconnect the electrical connectors. 3. Remove the mult1 function switch. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Page 746 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 750 Headlamp Dimmer Switch: Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 751 Headlamp Dimmer Switch: Description and Operation The integrated multifunction switch is mounted to the LH side of the steering column and controls the turn signal, headlamp dimmer/flash-to-pass, windshield wiper/washer and hazard warning. The ignition switch is mounted below the steering column and is activated using the ignition key and rotating the key lock cylinder on the steering column. If equipped with manual transmission, the key release lever prevents rotation of the ignition cylinder to LOCK or ACC positions unless the lever is depressed. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis Headlamp Dimmer Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 754 Headlamp Dimmer Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 755 Headlamp Dimmer Switch: Diagnostic Trouble Code Descriptions GEM/CTM Active Command Index Part 1 Of 2 Part 2 Of 2 GEM/CTM Diagnostic Trouble Code (DTC) Index Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 756 Part 1 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 757 Part 2 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 758 Part 3 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 759 Part 4 Of 4 GEM/CTM Parameter Identification (PID) Index Part 1 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 760 Part 2 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 761 Part 3 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 762 Headlamp Dimmer Switch: Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 763 Headlamp Dimmer Switch: Testing and Inspection Flow of Diagnosis 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Initial Inspection and Diagnostic Overview Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 764 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures GEM/CTM Active Command Index Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 765 Part 1 Of 2 Part 2 Of 2 GEM/CTM Diagnostic Trouble Code (DTC) Index Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 766 Part 1 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 767 Part 2 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 768 Part 3 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 769 Part 4 Of 4 GEM/CTM Parameter Identification (PID) Index Part 1 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 770 Part 2 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 771 Part 3 Of 3 Symptom Related Diagnostic Procedures Part 1 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 772 Part 2 Of 2 Test A: No Communication With the GEM or CTM Test A1 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 773 Test A2 - A3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 774 Test A4 - A5 Test B: Unable to Enter Self-Test Test B1 Test C: the Ignition Switch Is Inoperative Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 775 Test C1 Test D: No Power In ACC Test D1 Test E: No Power In Run Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 776 Test E1 Test E1 - E2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 777 Test F: No Power In Start Test F1 - F2 Component Tests and General Diagnostics Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 778 Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 779 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 780 Headlamp Dimmer Switch: Service and Repair MULTIFUNCTION SWITCH Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1. Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2. Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder 3. Twist the tilt wheel handle and shank and remove. 4. NOTE: Move gear selector to lowest position to access steering column opening cover. Release the four clips and remove the steering column opening cover. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 781 5. Remove the upper and lower steering column shrouds. 1. Remove the three screws. 2. Remove the lower steering column shroud. 3. Remove the upper steering column shroud. 6. Remove the mult1 function switch. 1. Remove the two screws. 2. Disconnect the electrical connectors. 3. Remove the mult1 function switch. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 782 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams Headlamp Switch: Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 786 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 787 Headlamp Switch: Testing and Inspection Component Testing Procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 788 Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 789 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 790 Headlamp Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Turn the headlamp switch knob to the headlamp position and pull the knob. 3. Insert a thin tool to release the headlamp switch knob and remove. 4. Turn the headlamp switch knob 180 degrees and install. 5. Turn counterclockwise until the back of the headlamp switch knob is in the OFF position. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 791 6. Turn the headlamp switch knob fully clockwise. 7. Remove the headlamp switch. 1 Pull the headlamp switch from the instrument panel. 2 Disconnect the electrical connectors. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service and Repair Horn Switch: Service and Repair NOTE: The steering wheel pad horn switch is part of the driver side air bag module. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Service and Repair Interior Light Switch: Service and Repair Switch - Interior Lamp Removal 1. Remove the front door trim panel. Please refer to Body and Frame/Doors, Hood and Trunk/Door/Door Panel/Service and Repair/ See: Body and Frame/Doors, Hood and Trunk/Doors 2. Remove the interior lamp switch. a. Disconnect the interior lamp switch electrical connector. b. Rotate interior lamp switch counterclockwise and remove. Installation 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 801 Turn Signal Switch: Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 802 Turn Signal Switch: Description and Operation The integrated multifunction switch is mounted to the LH side of the steering column and controls the turn signal, headlamp dimmer/flash-to-pass, windshield wiper/washer and hazard warning. The ignition switch is mounted below the steering column and is activated using the ignition key and rotating the key lock cylinder on the steering column. If equipped with manual transmission, the key release lever prevents rotation of the ignition cylinder to LOCK or ACC positions unless the lever is depressed. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis Turn Signal Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 805 Turn Signal Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 806 Turn Signal Switch: Diagnostic Trouble Code Descriptions GEM/CTM Diagnostic Trouble Code (DTC) Index Part 1 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 807 Part 2 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 808 Part 3 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 809 Part 4 Of 4 GEM/CTM Active Command Index Part 1 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 810 Part 2 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 811 Turn Signal Switch: Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 812 Turn Signal Switch: Testing and Inspection Flow of Diagnosis 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Initial Inspection and Diagnostic Overview Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 813 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures GEM/CTM Diagnostic Trouble Code (DTC) Index Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 814 Part 1 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 815 Part 2 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 816 Part 3 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 817 Part 4 Of 4 GEM/CTM Active Command Index Part 1 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 818 Part 2 Of 2 Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 819 Component Tests and General Diagnostics Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 820 Schematic Pinout Values and Diagnostic Parameters Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 821 Part 1 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 822 Part 2 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 823 Part 3 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Page 824 Turn Signal Switch: Service and Repair MULTIFUNCTION SWITCH Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1. Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2. Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder 3. Twist the tilt wheel handle and shank and remove. 4. NOTE: Move gear selector to lowest position to access steering column opening cover. Release the four clips and remove the steering column opening cover. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Page 825 5. Remove the upper and lower steering column shrouds. 1. Remove the three screws. 2. Remove the lower steering column shroud. 3. Remove the upper steering column shroud. 6. Remove the mult1 function switch. 1. Remove the two screws. 2. Disconnect the electrical connectors. 3. Remove the mult1 function switch. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Page 826 Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Revised Article No. 01-21-6 10/29/01 ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE MERCURY HOOD LAMP SWITCH FORD: 1987-1995 TAURUS 1988-1991 CROWN VICTORIA 1989 THUNDERBIRD 1989-1996 MUSTANG 1994-1996 THUNDERBIRD 1990 BRONCO II 1990-1996 RANGER 1991-1996 BRONCO 1994-2001 EXPLORER 1997-2001 F-150 2000-2001 EXCURSION 2002 EXPEDITION LINCOLN: 1989-1994 CONTINENTAL 1990-1992 MARK VII 1990-1996 TOWN CAR 1993-1995 MARK VIII 2002 NAVIGATOR MERCURY: 1987-1995 SABLE 1988-1991 GRAND MARQUIS 1989 COUGAR 1994-1996 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is to provide information on replacement hood lamp switches. The 27 degree Mercury style hood switches will no longer be available. Replacement 27 degree Mechanical switches will be available as a service replacement. ACTION For vehicles requiring hood lamp switch replacement, replace the 27 degree Mercury switch with new 27 degree Mechanical switch. Replace hood lamp switch per the appropriate model year Workshop Manual as needed. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised > Page 831 OASIS CODES: 201000, 201200 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 842 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 843 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 849 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 850 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 851 Air Flow Meter/Sensor: Specifications Mass Airflow Sensor (MAF) Plate Nuts 8-11.5 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 852 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 853 Air Flow Meter/Sensor: Service and Repair REMOVAL WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. THE SENSOR CAN BE DAMAGED BY TOUCHING. 1. Disconnect the battery ground cable. 2. Open the engine air cleaner. ^ Disconnect the Mass Air Flow (MAF) sensor connector from the wiring harness. ^ Release the air cleaner clamp. ^ Separate the inlet side of the air cleaner from the outlet side of the air cleaner. 3. Cut the tape on the wire loom of the extension harness. ^ Peel back the wire loom from the extension harness near the grommet in the air cleaner. CAUTION: Do not cut the MAF sensor wires when cutting the tape on the wire loom. 4. Remove the grommet from the outlet side of the air cleaner and slide the grommet down the extension harness. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 854 5. Remove the MAF sensor plate and mass air flow sensor from the outlet side of the engine air cleaner. 6. Disconnect the MAF sensor connector. 7. Remove the nuts and separate the MAF plate from the mass air flow sensor. INSTALLATION 1. Follow the removal procedure in reverse order. CAUTION ^ Do not tamper with the MAF sensing elements located in the airflow bypass; tampering may result in unit failure. ^ The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. NOTE ^ The MAF sensor module and body are calibrated and replaced as a unit. ^ Use the alignment notch to properly align the inlet side and the outlet side of the engine air cleaner. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 863 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 864 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 865 DISCLAIMER Service Procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 866 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 867 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 868 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 869 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 870 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 871 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 872 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 873 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 874 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 875 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 881 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 882 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 883 DISCLAIMER Service Procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 884 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 885 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 886 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 887 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 888 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 889 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 890 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 891 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 892 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 893 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 894 Camshaft Position Sensor: Specifications Camshaft Position (CMP) Sensor Bolt 8-12 Nm Camshaft Position Sensor 8-12 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 895 Camshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Camshaft Position (CMP) sensor 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the camshaft position sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams > Page 899 Clutch Switch: Service and Repair REMOVAL 1. Disconnect electrical connector from clutch pedal position switch. 2. Release the clutch pedal position switch from the orientation clip. 3. Remove the plastic retainer. 1 Push the lock tabs together. 2 Slide the plastic retainer off the clutch pedal position switch. 4. Remove the clutch pedal position switch. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor (ECT) 16-24 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications Engine Temperature Sensor: Specifications Cylinder Head Temperature (CHT) Sensor 6.9-13.5 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications > Page 906 Engine Temperature Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Remove the Cylinder Head Temperature (CHT) sensor. 1 Disconnect the connector. 2 Remove the CHT sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service and Repair Fuel Tank Pressure Sensor: Service and Repair REMOVAL 1. Remove the fuel tank. 2. Disconnect the electrical connector. CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Push down while rotating the sensor counterclockwise to disengage it from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. 3. Press down and rotate the fuel tank pressure sensor counterclockwise and remove it from the fuel tank. INSTALLATION 1. To install, reverse the removal procedure. 2. Leak test the system. 3. Carry out the Evaporative Emission Running Loss Monitor Repair Verification Drive Cycle Test. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair Intake Air Temperature Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the connector. 3. Remove the intake air temperature sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Linear Knock Sensor 16.2-23.8 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 916 Knock Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Remove the knock sensor. 1 Disconnect the connector. 2 Remove the knock sensor. NOTE: This engine is equipped with a unique linear knock sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics Oxygen Sensor: Technical Service Bulletins Engine Controls - Bi-Fuel O2 Sensor Diagnostics Article No. 03-6-6 03/31/03 DRIVEABILITY - BI-FUEL - OXYGEN SENSOR DIAGNOSTICS - HIGH OXYGEN SENSOR VOLTAGE READING FORD: 1998-2000 CONTOUR 1998-1999 E SERIES 1998-2003 F-150 1999 F-250 ISSUE Some Bi-Fuel vehicles may exhibit DTC's for high Oxygen Sensor voltage (P0132 and P0152). Current diagnostics may result in premature replacement of the Compuvalve. ACTION If an Oxygen Sensor code is set, the current diagnostics direct the Compuvalve to be replaced it no faults are detected when Pinpoint Test H is conducted. The modified repair action outlined below gives additional test procedures if nothing is detected from Pinpoint Test H. SERVICE PROCEDURE 1. Prior to clearing any codes, to aid in diagnostics of intermittent failures, access and record the freeze frame data using the NGS Tester. 2. At step H4 of the pinpoint test, it Oxygen Sensor PIDS (H02S11 and H02521) are within specification (see table in Section H of PC/ED Manual), clear codes and road test the vehicle in alternative fuel using the freeze frame data (from above) to duplicate conditions that triggered the code. During the road test, monitor Oxygen Sensor PIDs for both banks in both the PCM and the AFCM. NOTE A SECOND TECHNICIAN SHOULD MONITOR THE PIDS WHILE THE OTHER DRIVES. IF THE CODE/CONCERN CANNOT BE DUPLICATED, REFER TO PINPOINT TEST Z OF THE BASE VEHICLE PC/ED. 3. If the concern is duplicated, and if voltage is outside of specifications in both the AFCM and the PCM, the fault is in the Heated Exhaust Gas Oxygen (HEGO) sensor circuit. Refer to base vehicle diagnostics. 4. If the voltage is outside of specifications in the AFCM only, replace the Compuvalve. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 490000, 698298 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 921 Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 922 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 923 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 924 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 925 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 926 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 927 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 928 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 929 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 930 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 931 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 932 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 933 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 934 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 935 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 936 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 937 Oxygen Sensor: Specifications Heated Oxygen Sensor (HO2S) 36-46 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > OBD-II Heated Oxygen Sensor Numbering Convention Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > OBD-II Heated Oxygen Sensor Numbering Convention > Page 940 Oxygen Sensor: Locations Component Location 4.2L/4.6L 5.4L/6.8L Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 943 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 944 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 945 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 946 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 947 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 948 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 949 Oxygen Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 950 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 951 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 952 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 953 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 954 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 955 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 956 Oxygen Sensor: Connector Views Oxygen Sensor Vehicle Harness Connector PCM Connector Pin Numbers Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) - Front Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) - Front Oxygen Sensor Wrench Special Tool(s) REMOVAL WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. NEVER ATTEMPT TO SERVICE ANY PART OF THE SYSTEM UNTIL IT HAS COOLED. BE ESPECIALLY CAREFUL WHEN WORKING AROUND THE THREE WAY CATALYTIC CONVERTER. THE TEMPERATURE OF THE THREE WAY CATALYTIC CONVERTER RISES TO A HIGH LEVEL AFTER ONLY A FEW MINUTES OF ENGINE OPERATION. 1. Turn the ignition switch OFF. 2. Disconnect the connector. 3. Raise and support the vehicle. 4. Use Oxygen Sensor Wrench to remove the heated oxygen sensor. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) - Front > Page 959 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) - Front > Page 960 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) - Rear Oxygen Sensor Wrench Special Tool(s) REMOVAL WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. NEVER ATTEMPT TO SERVICE ANY PART OF THE SYSTEM UNTIL IT HAS COOLED. BE ESPECIALLY CAREFUL WHEN WORKING AROUND THE THREE WAY CATALYTIC CONVERTER. THE TEMPERATURE OF THE THREE WAY CATALYTIC CONVERTER RISES TO A HIGH LEVEL AFTER ONLY A FEW MINUTES OF ENGINE OPERATION. 1. Turn the ignition switch OFF. 2. Raise and support the vehicle. 3. Remove the heated oxygen sensor. 1 Disconnect the connector. 2 Use the Oxygen Sensor Wrench to remove the heated oxygen sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications Pressure Feedback Exhaust Sensor: Specifications Differential Pressure Feedback EGR Sensor Nuts 8-12 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 964 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Remove the differential pressure feedback EGR sensor. 1 Remove the differential pressure feedback EGR sensor tubes. 2 Disconnect the differential pressure feedback EGR sensor electrical connector. 3 Remove the two nuts. 4 Remove the differential pressure feedback EGR sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position (TP) Sensor Screws 2.8-3.4 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 968 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the shield. 3. Remove the throttle position sensor. 1 Disconnect the connector. 2 Remove the bolts. 3 Remove the throttle position sensor. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 969 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > 4R70W Transmission Position Switch/Sensor: Specifications Digital Transmission Range Sensor Bolts 7-10 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > 4R70W > Page 974 Transmission Position Switch/Sensor: Specifications Digital Transmission TR Sensor 8-10 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 975 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W Transmission Position Switch/Sensor: Service and Repair 4R70W Special Tools 1. Raise and support vehicle. 2. Disconnect the manual lever shift control cable. 3. Disconnect the digital TR electrical connector. 4. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. The old nut will not retain torque specification. Remove the manual control lever. 1 Remove the nut. 2 Remove the lever. 5. Loosen the digital TR sensor bolts. 6. NOTE: Manual shift lever must be in the neutral position. Use digital transmission range TR Sensor Alignment Tool, to align the digital TR sensor slots. The tool is designed to fit snug. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W > Page 978 7. Tighten the bolts. 8. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual lever shaft outer nut. 9. With the manual lever in overdrive connect the shift lever control cable. 10. Install the digital TR sensor electrical connector. 11. Lower the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W > Page 979 Transmission Position Switch/Sensor: Service and Repair 4R100 Special Tools Removal 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Disconnect the connector. 4. Disconnect the shift cable at the manual control lever. 5. Remove the digital Transmission Range (TR) sensor. 1 Remove the bolts. 2 Remove the digital Transmission Range (TR) sensor. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W > Page 980 1. Install the digital Transmission Range (TR) sensor. 1 Install digital Transmission Range (TR) sensor. 2 Loosely install the bolts. 2. NOTE: Make sure that the manual control lever is in the neutral position. Install the Digital Transmission Range (TR) Sensor Alignment Tool. The tool is designed to fit snug. 3. Tighten the bolts. 4. Reconnect the shift cable at the manual control lever. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W > Page 981 5. Reconnect the connector. 6. Lower the vehicle. 7. Reconnect the battery ground cable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Tools and Equipment > 4R70W Special Tool Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Tools and Equipment > 4R70W > Page 984 Special Tool Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications Vehicle Speed Sensor Bolt 11-13 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 990 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 991 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 992 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 993 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 994 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 995 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 996 Vehicle Speed Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 997 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 998 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 999 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1001 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 1002 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications Pressure Feedback Exhaust Sensor: Specifications Differential Pressure Feedback EGR Sensor Nuts 8-12 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 1007 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Remove the differential pressure feedback EGR sensor. 1 Remove the differential pressure feedback EGR sensor tubes. 2 Disconnect the differential pressure feedback EGR sensor electrical connector. 3 Remove the two nuts. 4 Remove the differential pressure feedback EGR sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 1017 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 1018 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 1024 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 1025 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 1026 Air Flow Meter/Sensor: Specifications Mass Airflow Sensor (MAF) Plate Nuts 8-11.5 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 1027 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 1028 Air Flow Meter/Sensor: Service and Repair REMOVAL WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. THE SENSOR CAN BE DAMAGED BY TOUCHING. 1. Disconnect the battery ground cable. 2. Open the engine air cleaner. ^ Disconnect the Mass Air Flow (MAF) sensor connector from the wiring harness. ^ Release the air cleaner clamp. ^ Separate the inlet side of the air cleaner from the outlet side of the air cleaner. 3. Cut the tape on the wire loom of the extension harness. ^ Peel back the wire loom from the extension harness near the grommet in the air cleaner. CAUTION: Do not cut the MAF sensor wires when cutting the tape on the wire loom. 4. Remove the grommet from the outlet side of the air cleaner and slide the grommet down the extension harness. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 1029 5. Remove the MAF sensor plate and mass air flow sensor from the outlet side of the engine air cleaner. 6. Disconnect the MAF sensor connector. 7. Remove the nuts and separate the MAF plate from the mass air flow sensor. INSTALLATION 1. Follow the removal procedure in reverse order. CAUTION ^ Do not tamper with the MAF sensing elements located in the airflow bypass; tampering may result in unit failure. ^ The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. NOTE ^ The MAF sensor module and body are calibrated and replaced as a unit. ^ Use the alignment notch to properly align the inlet side and the outlet side of the engine air cleaner. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Specifications Inertia Fuel Shutoff Switch: Specifications Intertia Fuel Shutoff Switch Bolts .............................................................................................................................................. 1.6-2.2 N.m (14.2-19 Lb-In) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position (TP) Sensor Screws 2.8-3.4 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 1036 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the shield. 3. Remove the throttle position sensor. 1 Disconnect the connector. 2 Remove the bolts. 3 Remove the throttle position sensor. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 1037 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1047 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1048 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1049 DISCLAIMER Service Procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1050 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1051 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1052 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1053 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1054 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1055 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1056 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1057 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1058 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1059 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1065 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1066 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1067 DISCLAIMER Service Procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1068 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1069 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1070 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1071 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1072 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1073 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1074 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1075 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1076 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1077 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 1078 Camshaft Position Sensor: Specifications Camshaft Position (CMP) Sensor Bolt 8-12 Nm Camshaft Position Sensor 8-12 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 1079 Camshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Camshaft Position (CMP) sensor 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the camshaft position sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1088 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1089 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1090 DISCLAIMER Service Procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1091 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1092 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1093 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1094 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1095 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1096 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1097 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1098 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1099 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1100 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1106 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1107 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1108 DISCLAIMER Service Procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1109 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1110 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1111 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1112 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1113 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1114 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1115 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1116 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1117 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 1118 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 1124 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 1125 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 1126 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 1127 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 1128 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 1129 Ignition Switch Lock Cylinder: Specifications TORQUE SPECIFICATIONS Lock Cylinder Housing Screws .................................................................................................................................................. 18-26 Nm (14-19 ft. lbs.) Key Release Button Bolt ............................................................................................................................................................ 4-6 Nm (36-53 inch lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Lock Cylinder Ignition Switch Lock Cylinder: Service and Repair Functional Lock Cylinder Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1. Insert the ignition key and turn to the RUN position. 2. Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock cylinder. Installation 1. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Lock Cylinder > Page 1132 Ignition Switch Lock Cylinder: Service and Repair Key Release Button Removal 1. Remove the ignition switch lock cylinder. 1. Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2. Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. 2. Twist the tilt wheel handle and shank and remove. 3. Release the four clips and remove the steering column opening cover. 4. Remove the upper and lower steering column shrouds. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Lock Cylinder > Page 1133 1. Remove the three screws. 2. Remove the lower steering column shroud. 3. Remove the upper steering column shroud. 5. Remove the key release button. 1. Remove the bolt. 2. Remove the spring. 3. Remove the key release button. Installation 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Lock Cylinder > Page 1134 Ignition Switch Lock Cylinder: Service and Repair Non-Functional Lock Cylinder Removal WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Lock Cylinder > Page 1135 4. Remove the ignition switch lock cylinder. ^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. ^ Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. ^ Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. 6. Remove the bearing and the gear. ^ Thoroughly clean all drill shavings from the steering column and inspect it for damage. Installation The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Lock Cylinder > Page 1136 1. NOTE: Use a new ignition switch lock cylinder. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Linear Knock Sensor 16.2-23.8 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 1140 Knock Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Remove the knock sensor. 1 Disconnect the connector. 2 Remove the knock sensor. NOTE: This engine is equipped with a unique linear knock sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Description and Operation Air Bag Deactivation Switch: Description and Operation The Passenger Air Bag Deactivation (PAD) switch: - is located on the instrument panel to the right of the climate controls. - contains a Light Emitting Diode (LED) that indicates when the PAD switch is activated (passenger air bag disabled). - allows the passenger air bag deployment circuit to be disabled using the ignition key. - should be used whenever a child safety seat is being used in the front passenger seating position. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Description and Operation > Page 1145 Air Bag Deactivation Switch: Service and Repair REMOVAL WARNING: To avoid accidental, deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). NOTE: Repair is made by installing a new part only. If a new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the center instrument panel finish panel. 3. Remove the Passenger Air Bag Deactivation (PAD) switch. 1 Disconnect the electrical connector. 2 Remove the retaining bolts. 3 Remove the PAD switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Repair is made by installing a new part only If a new part does not correct the condition, install the original part and perform the diagnostic procedure again. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation Impact Sensor: Description and Operation WARNING: The Restraints Control Module (RCM) orientation is critical for correct system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) has been involved in a collision in which the center tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, the RCM must be replaced whether or not the air bags have deployed. In addition, make sure the area of the RCM mounting is restored to its original condition. The SRS contains two sensors which are integral to the Restraints Control Module (RCM). The RCM is mounted on the center tunnel under the instrument panel. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 1153 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 1154 Clutch Switch: Description and Operation The Clutch Pedal Position (CPP) switch is controlled by the clutch pedal. Depressing the clutch pedal manually closes the CPP switch and allows engine cranking. The CPP switch will also deactivate the speed control system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 1155 Clutch Switch: Service and Repair REMOVAL 1. Disconnect the Clutch Pedal Position switch (CPP) electrical connector. 2. Release the clutch pedal position switch from the orientation clip. 3. Remove the plastic retainer. 1 Push the lock tabs together. 2 Slide the plastic retainer off the clutch pedal position switch. 4. Remove the clutch pedal position switch. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 1161 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 1162 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 1163 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 1164 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 1165 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 1166 Ignition Switch Lock Cylinder: Specifications TORQUE SPECIFICATIONS Lock Cylinder Housing Screws .................................................................................................................................................. 18-26 Nm (14-19 ft. lbs.) Key Release Button Bolt ............................................................................................................................................................ 4-6 Nm (36-53 inch lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Lock Cylinder Ignition Switch Lock Cylinder: Service and Repair Functional Lock Cylinder Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1. Insert the ignition key and turn to the RUN position. 2. Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock cylinder. Installation 1. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Lock Cylinder > Page 1169 Ignition Switch Lock Cylinder: Service and Repair Key Release Button Removal 1. Remove the ignition switch lock cylinder. 1. Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2. Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. 2. Twist the tilt wheel handle and shank and remove. 3. Release the four clips and remove the steering column opening cover. 4. Remove the upper and lower steering column shrouds. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Lock Cylinder > Page 1170 1. Remove the three screws. 2. Remove the lower steering column shroud. 3. Remove the upper steering column shroud. 5. Remove the key release button. 1. Remove the bolt. 2. Remove the spring. 3. Remove the key release button. Installation 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Lock Cylinder > Page 1171 Ignition Switch Lock Cylinder: Service and Repair Non-Functional Lock Cylinder Removal WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Lock Cylinder > Page 1172 4. Remove the ignition switch lock cylinder. ^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. ^ Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. ^ Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. 6. Remove the bearing and the gear. ^ Thoroughly clean all drill shavings from the steering column and inspect it for damage. Installation The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Lock Cylinder > Page 1173 1. NOTE: Use a new ignition switch lock cylinder. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair Steering Angle Sensor: Service and Repair Removal CAUTION: The steering column must be in the locked position, or the lower end of the column wired in such a way that the steering column does not rotate, resulting in damage to the air bag sliding, contact. NOTE: Discard the upper intermediate shaft to steering column shaft bolt upon removal. Do not reuse; replace with new bolts. 1. Remove the bolt retaining the upper shaft assembly U-joint to the steering column center shaft. 2. Remove the shock absorber electronic steering sensor. 1. Disconnect the electrical connector. 2. Remove the screws. 3. Remove the shock absorber electronic steering sensor. 3. Remove the sensor ring. 1. Remove the steering column lower bearing spring. 2. Remove the sensor ring. Installation 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Page 1182 2. Install the shock absorber electronic steering sensor. 1. Position the shock absorber electronic steering sensor. 2. Install the screws. 3. Connect the electrical connector. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair Steering Angle Sensor: Service and Repair Removal CAUTION: The steering column must be in the locked position, or the lower end of the column wired in such a way that the steering column does not rotate, resulting in damage to the air bag sliding, contact. NOTE: Discard the upper intermediate shaft to steering column shaft bolt upon removal. Do not reuse; replace with new bolts. 1. Remove the bolt retaining the upper shaft assembly U-joint to the steering column center shaft. 2. Remove the shock absorber electronic steering sensor. 1. Disconnect the electrical connector. 2. Remove the screws. 3. Remove the shock absorber electronic steering sensor. 3. Remove the sensor ring. 1. Remove the steering column lower bearing spring. 2. Remove the sensor ring. Installation 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Page 1187 2. Install the shock absorber electronic steering sensor. 1. Position the shock absorber electronic steering sensor. 2. Install the screws. 3. Connect the electrical connector. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Specifications Suspension Mode Switch: Specifications TORQUE SPECIFICATIONS Air Suspension Switch Bracket Bolt ............................................................................................................................... 10.2-13.8 Nm (91-123 inch lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Description and Operation Overdrive Switch: Description and Operation The Transmission Control Switch (TCS) is a momentary contact switch that is located on the end of the transmission control selector lever. Pushing the TCS will either disengage or engage the overdrive function of the transmission. if the OVERDRIVE is disengaged, the word OFF will illuminate on the transmission control selector lever. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Description and Operation > Page 1196 Overdrive Switch: Service and Repair Removal 1. Remove the Transmission Control Switch (TCS). 1 Remove the TCS cover. 2 Remove the TCS. Installation 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > 4R70W Transmission Position Switch/Sensor: Specifications Digital Transmission Range Sensor Bolts 7-10 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > 4R70W > Page 1201 Transmission Position Switch/Sensor: Specifications Digital Transmission TR Sensor 8-10 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 1202 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W Transmission Position Switch/Sensor: Service and Repair 4R70W Special Tools 1. Raise and support vehicle. 2. Disconnect the manual lever shift control cable. 3. Disconnect the digital TR electrical connector. 4. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. The old nut will not retain torque specification. Remove the manual control lever. 1 Remove the nut. 2 Remove the lever. 5. Loosen the digital TR sensor bolts. 6. NOTE: Manual shift lever must be in the neutral position. Use digital transmission range TR Sensor Alignment Tool, to align the digital TR sensor slots. The tool is designed to fit snug. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W > Page 1205 7. Tighten the bolts. 8. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual lever shaft outer nut. 9. With the manual lever in overdrive connect the shift lever control cable. 10. Install the digital TR sensor electrical connector. 11. Lower the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W > Page 1206 Transmission Position Switch/Sensor: Service and Repair 4R100 Special Tools Removal 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Disconnect the connector. 4. Disconnect the shift cable at the manual control lever. 5. Remove the digital Transmission Range (TR) sensor. 1 Remove the bolts. 2 Remove the digital Transmission Range (TR) sensor. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W > Page 1207 1. Install the digital Transmission Range (TR) sensor. 1 Install digital Transmission Range (TR) sensor. 2 Loosely install the bolts. 2. NOTE: Make sure that the manual control lever is in the neutral position. Install the Digital Transmission Range (TR) Sensor Alignment Tool. The tool is designed to fit snug. 3. Tighten the bolts. 4. Reconnect the shift cable at the manual control lever. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W > Page 1208 5. Reconnect the connector. 6. Lower the vehicle. 7. Reconnect the battery ground cable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Tools and Equipment > 4R70W Special Tool Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Tools and Equipment > 4R70W > Page 1211 Special Tool Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed Sensor Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed Sensor > Page 1216 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 1217 Transmission Speed Sensor: Service and Repair Removal 1. Remove the drive shaft. 2. Remove the rear transmission mount nuts. 3. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the TSS and OSS sensors will occur. Remove the rear transmission mount. 1 Raise the transmission up off the rear crossmember support. 2 Remove the bolts. 3 Remove the rear transmission mount. 4. Lower the transmission to gain access to the Turbine Shaft Speed (TSS) sensor, and the Output Shaft Speed (OSS) sensor. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 1218 5. Remove the Turbine Shaft Sensor (TSS). 1 Remove the bolt. 2 Remove the Turbine Shaft Sensor (TSS). 6. Remove the Output Shaft Speed (OSS) sensor. 1 Remove the bolt. 2 Remove the Output Shaft Speed (OSS) sensor. Installation 1. Install the Output Shaft Speed (OSS) sensor. 1 Lubricate the O-ring and install the Output Shaft Speed (OSS) sensor. 2 Install the bolt. 2. Install the Turbine Shaft Sensor (TSS). 1 Lubricate the O-ring and install the Turbine Shaft Sensor (TSS). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 1219 2 Install the bolt. 3. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the sensors will occur. Install the rear transmission mount. 1 Raise the transmission up. 2 Install the rear transmission mount. 3 Install the bolts. 4. Lower the transmission on to the rear crossmember support. 5. Install the rear transmission mount nuts. 6. Install the drive shaft. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Output Shaft Speed Sensor Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Output Shaft Speed Sensor > Page 1225 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 1226 Transmission Speed Sensor: Service and Repair Removal 1. Remove the drive shaft. 2. Remove the rear transmission mount nuts. 3. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the TSS and OSS sensors will occur. Remove the rear transmission mount. 1 Raise the transmission up off the rear crossmember support. 2 Remove the bolts. 3 Remove the rear transmission mount. 4. Lower the transmission to gain access to the Turbine Shaft Speed (TSS) sensor, and the Output Shaft Speed (OSS) sensor. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 1227 5. Remove the Turbine Shaft Sensor (TSS). 1 Remove the bolt. 2 Remove the Turbine Shaft Sensor (TSS). 6. Remove the Output Shaft Speed (OSS) sensor. 1 Remove the bolt. 2 Remove the Output Shaft Speed (OSS) sensor. Installation 1. Install the Output Shaft Speed (OSS) sensor. 1 Lubricate the O-ring and install the Output Shaft Speed (OSS) sensor. 2 Install the bolt. 2. Install the Turbine Shaft Sensor (TSS). 1 Lubricate the O-ring and install the Turbine Shaft Sensor (TSS). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 1228 2 Install the bolt. 3. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the sensors will occur. Install the rear transmission mount. 1 Raise the transmission up. 2 Install the rear transmission mount. 3 Install the bolts. 4. Lower the transmission on to the rear crossmember support. 5. Install the rear transmission mount nuts. 6. Install the drive shaft. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Specifications Four Wheel Drive Selector Switch: Specifications 4WD Indicator Switch .......................................................................................................................... ................................................ 41 Nm (30 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Specifications > Page 1233 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Specifications > Page 1234 Four Wheel Drive Selector Switch: Service and Repair Removal 1. Remove the center instrument panel trim plate. 2. Remove the shift range selector switch. 1 Remove the shift range selector switch knob. 2 Disconnect the shift range selector switch electrical connector. 3 Remove the two shift range selector switch bolts. 4 Remove the shift range selector switch. Installation 1. Install the shift range selector switch. 1 Position the shift range selector switch. 2 Install the bolts. 3 Install the electrical connector. 4 Install the knob. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Specifications > Page 1235 2. Install the center instrument panel trim plate. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Page 1239 Gear Sensor/Switch: Service and Repair Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the 4WD indicator switch. 1 Disconnect the 4WD indicator switch electrical connector. 2 Remove the 4WD indicator switch. Installation 1. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Specifications Speed Sensor: Specifications Output Shaft Speed Sensor 4 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Specifications > Page 1243 Speed Sensor: Service and Repair Removal 1. Remove the output shaft speed sensor connector. 2. Remove the bolt and the output shaft speed sensor. Installation 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Driver's Power Window Switch Power Window Switch: Diagrams Driver's Power Window Switch Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Driver's Power Window Switch > Page 1249 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 1250 Power Window Switch: Description and Operation The window regulator control switch: - Is located on each front door trim panel. - May be used to raise or lower both driver side and passenger side windows from the master control on the driver side, or the passenger side window from the passenger side switch. - Includes a "double detent" feature. - Can manually lower the driver side window when the master control is depressed half way (first detent). - Will completely lower the driver side window when the master control is fully depressed (second detent) and then released. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Left Power Window Switch: Testing and Inspection Left Component Testing Procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Left > Page 1253 Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Left > Page 1254 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Left > Page 1255 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Left > Page 1256 Power Window Switch: Testing and Inspection Right Window Switch Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Left > Page 1257 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 1258 Power Window Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the window regulator switch plate. 1 Pry up the window regulator switch plate. 2 Disconnect the electrical connectors. 3. Remove the window regulator control switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery ground cable is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 1263 Windshield Washer Switch: Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 1264 Windshield Washer Switch: Description and Operation The integrated multifunction switch is mounted to the LH side of the steering column and controls the turn signal, headlamp dimmer/flash-to-pass, windshield wiper/washer and hazard warning. The ignition switch is mounted below the steering column and is activated using the ignition key and rotating the key lock cylinder on the steering column. If equipped with manual transmission, the key release lever prevents rotation of the ignition cylinder to LOCK or ACC positions unless the lever is depressed. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis Windshield Washer Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1267 Windshield Washer Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1268 Windshield Washer Switch: Diagnostic Trouble Code Descriptions GEM/CTM Active Command Index Part 1 Of 2 Part 2 Of 2 GEM/CTM Diagnostic Trouble Code (DTC) Index Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1269 Part 1 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1270 Part 2 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1271 Part 3 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1272 Part 4 Of 4 GEM/CTM Parameter Identification (PID) Index Part 1 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1273 Part 2 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1274 Part 3 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1275 Windshield Washer Switch: Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1276 Windshield Washer Switch: Testing and Inspection Flow of Diagnosis 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Initial Inspection and Diagnostic Overview Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1277 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures GEM/CTM Active Command Index Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1278 Part 1 Of 2 Part 2 Of 2 GEM/CTM Diagnostic Trouble Code (DTC) Index Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1279 Part 1 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1280 Part 2 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1281 Part 3 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1282 Part 4 Of 4 GEM/CTM Parameter Identification (PID) Index Part 1 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1283 Part 2 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1284 Part 3 Of 3 Symptom Related Diagnostic Procedures Part 1 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1285 Part 2 Of 2 Test A: No Communication With the GEM or CTM Test A1 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1286 Test A2 - A3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1287 Test A4 - A5 Test B: Unable to Enter Self-Test Test B1 Component Tests and General Diagnostics Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1288 Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1289 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 1290 Windshield Washer Switch: Service and Repair MULTIFUNCTION SWITCH Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1. Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2. Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder 3. Twist the tilt wheel handle and shank and remove. 4. NOTE: Move gear selector to lowest position to access steering column opening cover. Release the four clips and remove the steering column opening cover. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 1291 5. Remove the upper and lower steering column shrouds. 1. Remove the three screws. 2. Remove the lower steering column shroud. 3. Remove the upper steering column shroud. 6. Remove the mult1 function switch. 1. Remove the two screws. 2. Disconnect the electrical connectors. 3. Remove the mult1 function switch. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 1292 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 1296 Wiper Switch: Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 1297 Wiper Switch: Description and Operation The integrated multifunction switch is mounted to the LH side of the steering column and controls the turn signal, headlamp dimmer/flash-to-pass, windshield wiper/washer and hazard warning. The ignition switch is mounted below the steering column and is activated using the ignition key and rotating the key lock cylinder on the steering column. If equipped with manual transmission, the key release lever prevents rotation of the ignition cylinder to LOCK or ACC positions unless the lever is depressed. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis Wiper Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1300 Wiper Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1301 Wiper Switch: Diagnostic Trouble Code Descriptions GEM/CTM Active Command Index Part 1 Of 2 Part 2 Of 2 GEM/CTM Diagnostic Trouble Code (DTC) Index Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1302 Part 1 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1303 Part 2 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1304 Part 3 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1305 Part 4 Of 4 GEM/CTM Parameter Identification (PID) Index Part 1 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1306 Part 2 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1307 Part 3 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1308 Wiper Switch: Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1309 Wiper Switch: Testing and Inspection Flow of Diagnosis 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Initial Inspection and Diagnostic Overview Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1310 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures GEM/CTM Active Command Index Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1311 Part 1 Of 2 Part 2 Of 2 GEM/CTM Diagnostic Trouble Code (DTC) Index Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1312 Part 1 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1313 Part 2 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1314 Part 3 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1315 Part 4 Of 4 GEM/CTM Parameter Identification (PID) Index Part 1 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1316 Part 2 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1317 Part 3 Of 3 Symptom Related Diagnostic Procedures Part 1 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1318 Part 2 Of 2 Test A: No Communication With the GEM or CTM Test A1 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1319 Test A2 - A3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1320 Test A4 - A5 Test B: Unable to Enter Self-Test Test B1 Test C: the Ignition Switch Is Inoperative Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1321 Test C1 Test D: No Power In ACC Test D1 Test E: No Power In Run Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1322 Test E1 Test E1 - E2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1323 Test F: No Power In Start Test F1 - F2 Component Tests and General Diagnostics Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1324 Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 1325 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 1326 Wiper Switch: Service and Repair MULTIFUNCTION SWITCH Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1. Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2. Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder 3. Twist the tilt wheel handle and shank and remove. 4. NOTE: Move gear selector to lowest position to access steering column opening cover. Release the four clips and remove the steering column opening cover. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 1327 5. Remove the upper and lower steering column shrouds. 1. Remove the three screws. 2. Remove the lower steering column shroud. 3. Remove the upper steering column shroud. 6. Remove the mult1 function switch. 1. Remove the two screws. 2. Disconnect the electrical connectors. 3. Remove the mult1 function switch. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 1328 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1334 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1335 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1336 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1337 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1338 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1339 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1340 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1341 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1342 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1343 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1344 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1345 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1346 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1347 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1348 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1349 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1350 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1351 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1352 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1353 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1354 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1355 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1356 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1357 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1358 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1359 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1360 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1361 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1362 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1363 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1364 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1365 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1366 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1367 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1368 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1369 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1370 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1371 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1372 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1373 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1374 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1375 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1376 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1377 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1378 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1379 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1380 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1381 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1382 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1383 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1384 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1385 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1386 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1387 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1388 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1389 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1390 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1391 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1392 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1393 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1394 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1395 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1396 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1397 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1398 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1399 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1400 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1401 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1402 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1403 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1404 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1405 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1406 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1407 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1408 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1409 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1410 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1411 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1412 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1413 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1414 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1415 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1416 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1417 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1418 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1419 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1420 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1421 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1422 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1423 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1424 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1425 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1426 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1427 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 1428 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 1429 Alignment: Specifications Caster LH ........................................................................................................................................................ ....................................................... 4.6° ± 1.0° RH ............................................................................. .................................................................................................................................. 5.3° ± 1.0° Total/Split ............................................................................................................................................. ..................................................... -0.7° ± 0.7° Camber LH ........................................................................................................................................................ ...................................................... -0.1° ± 0.7° RH ............................................................................. ................................................................................................................................ -0.1° ± 0.7° Total/Split ............................................................................................................................................. ......................................................... 0° ± 0.7° Toe (Positive Value Is Toe-In, Negative Value Is Toe-Out) LH ........................................................................................................................................................ ................................................... 0.10° ± 0.15° RH ............................................................................. .............................................................................................................................. 0.10° ± 0.15° Total/Split ............................................................................................................................................. .................................................. 0.20° ± 0.25° Dogtracking - Max. (Centerline Of Front Tires Compared To Centerline Of Rear Tires) .......................................................................................................................................... 30 mm (1.2 inch) Clear Vision (Negative Value Is Counterclockwise) ......................................................................................................................................... -0.7 ± 3.0° Vehicle Ride Height Front .................................................................................................................................................... ............... 113 mm ± 19 mm (4.4 in. ± 0.75 in.) Rear ........................................................................... ........................................................................................................... 150-205 mm (5.9-8.1 in.) Vehicle Lean (Side-to-Side Height Differences) Front - Maximum ................................................................................................................................. ................................................ 12 mm (0.5 in.) Rear - Maximum ........................................................ ........................................................................................................................ 19 mm (0.75 in.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 1430 Alignment: Description and Operation WHEEL ALIGNMENT ANGLES Caster and camber are adjusted by means of adjustment slots cut into the upper control arm mounting brackets. Toe is adjusted by the use of the front wheel spindle tie rod adjusting sleeve. Negative and Positive Camber CAMBER Negative and Positive Camber Camber is the vertical tilt of the wheel when viewed from the front. Camber can be positive or negative and has a direct effect on tire wear. Caster And Frame Angle CASTER Caster is the deviation from vertical of an imaginary line drawn through the ball joints when viewed from the side. The caster specifications will give the vehicle the best directional stability characteristics when loaded and driven. The caster setting is not related to tire wear. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 1431 Caster And Frame Angle Negative Toe (Toe Out) TOE The vehicle toe setting: ^ affects tire wear and directional stability. ^ must be checked after adding after-market equipment, such as a snowplow or body. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 1432 RIDE HEIGHT Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 1433 Wheel Track WHEEL TRACK Dogtracking DOGTRACKING Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can give the illusion of dogtracking. WANDER Wander is the tendency of the vehicle to require frequent, random left and right steering wheel corrections to maintain a straight path down a level road. SHIMMY Shimmy, as observed by the driver, is large, consistent, rotational oscillations of the steering wheel resulting from large, side-to-side (lateral) tire/wheel movements. Shimmy is usually experienced near 64 km/h (40 mph), and can begin or be amplified when the tire contacts pot holes or irregularities in the road surface. NIBBLE Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with various road surfaces and observed by the driver as small rotational oscillations of the steering wheel. POOR RETURNABILITY/STICKY STEERING Poor returnability and sticky steering is used to described the poor return of the steering wheel to center after a turn or the steering correction is completed. DRIFT/PULL Pull is a tugging sensation, felt by the hands on the steering wheel, that must be overcome to keep the vehicle going straight. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 1434 Drift describes what a vehicle with this condition does with hands off the steering wheel. ^ A vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-ahead path and require constant steering input in the opposite direction to counteract the effect. ^ Drift/pull may be induced by conditions external to the vehicle (i.e., wind, road camber). POOR GROOVE FEEL Poor groove feel is characterized by little or no buildup of turning effort felt in the steering gear as the wheel is rocked slowly left and right within very small turns around center or straight-ahead (under 20 degrees of steering wheel turn). Efforts may be said to be "flat on center. " ^ Under 20 degrees of turn, most of the turning effort that builds up comes from the mesh of gear teeth in the steering gear. In this range, the steering wheel is not yet turned enough to feel the effort from the self-aligning forces at the road wheel or tire patch. ^ In the diagnosis of a roadability problem, it is important to understand the difference between wander and poor groove feel. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Caster and Camber Alignment: Service and Repair Caster and Camber 1. Loosen the nuts to a point where the upper suspension arm joints are snug. 2. NOTE: A pry bar can be used between the upper control arm and the frame pocket to aid in moving the arm. To increase caster and camber, use the following steps. 1. To increase caster, move the front of the upper control arm outboard and move the rear of the upper control arm inboard. 2. To increase camber, move the upper control arm outboard equally. 3. To decrease caster and camber, use the following steps. 1. To decrease caster, move the front of the upper control arm inboard and move the rear of the upper control arm outboard. 2. To decrease camber, move the upper control arm inboard equally. 4. NOTE: Each increment of the notches on the frame pocket represents 0.3 degree. Set the caster and camber to specifications. ^ If a caster increase of 0.9 degree is required, move the front of the upper control arm outboard by 3 notches and move the rear of the upper control arm inboard by 3 notches. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Caster and Camber > Page 1437 5. Tighten the nuts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Caster and Camber > Page 1438 Alignment: Service and Repair Toe 1. Start the engine and center the steering wheel. 2. Turn the engine off, and hold the steering wheel in the "straight forward" position by attaching a rigid link from the steering wheel to the brake pedal. 3. Check the toe settings; follow the alignment rack manufacturer's instructions. 4. Hold the tie rod end while loosening the nuts. ^ Clean and lubricate the steering linkage and tie rod end threads. 5. Rotate the front wheel spindle tie rod adjusting sleeve to the desired position. 6. Tighten the nuts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Caster and Camber > Page 1439 7. Recheck the toe settings; follow the alignment rack manufacturer's instructions. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications Fuel Pressure Test Port: Specifications Fuel pressure relief valve 8 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 1445 Fuel Pressure Test Port: Service and Repair REMOVAL WARNING ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Release fuel pressure. 2. Remove the pressure relief valve. INSTALLATION 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > With 4R70W Idle Speed: Specifications With 4R70W Hot Idle ................................................................................................................................................ .................................................................. 720 RPM Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > With 4R70W > Page 1450 Idle Speed: Specifications With 4R100 Hot Idle ................................................................................................................................................ ......................................................... 760 - 830 RPM Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair REMOVAL 1. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the shield. 2. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. 3. Disconnect the (A) Positive Crankcase Ventilation (PCV) hose and the (B) Idle Air Control (IAC) valve inlet tube. 4. Loosen the clamps and remove the air cleaner outlet tube and resonator. INSTALLATION 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 1455 CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. NOTE: The inlet air cleaner has an alignment tab which fits into a slot on the outlet air cleaner. Make sure the tabs are aligned correctly. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair REMOVAL 1. Open the (A) air cleaner clamp and set the (B) outlet Air Cleaner (ACL) aside. 2. Remove the (A) Air Cleaner (ACL) element from the (B) open end of inlet. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. NOTE: The inlet air cleaner has an alignment tab which fits into a slot on the outlet air cleaner. Make sure tabs are aligned correctly. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Gauge Special Tool(s) WARNING - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the Schrader valve cap and install the Fuel Pressure Gauge. 2. Open the manual valve slowly on the Fuel Pressure Gauge and relieve the fuel pressure. - This will drain some fuel out of the system. Place the fuel in a suitable container. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications The RH (Passenger's) side ................................................................................................................. ................................................ Cylinders 1, 2, 3, and 4 The LH (Driver's side) .......................................................................................................................... ............................................. Cylinders 5, 6, 7 and 8 Firing Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Spark Plug: Specifications Spark Plug Gap 1.32-1.42 mm Spark Plugs 15 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap > Page 1474 Spark Plug: Specifications Spark Plug Gap 1.32-1.42 mm Spark Plugs 15 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1475 Spark Plug: Application and ID Original Spark Plug .............................................................................................................................. ............................................................... AWSF12E Replacement Spark Plug ................................... ................................................................................................................................................... AWSF12E Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1476 Spark Plug: Description and Operation The spark plug: ^ changes high-voltage pulses to sparks at gap which ignites fuel and air mixture. ^ originally equipped on the vehicle; has a platinum-enhanced active electrode for long life. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1477 Spark Plug: Service and Repair REMOVAL 1. Remove the Coil On Plug (COP). Remove the screw and the coil for each plug. NOTE: Remove any foreign debris from the spark plug wells with compressed air. 2. Remove the RH spark plugs. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1478 3. Remove the LH spark plugs. 4. Inspect the spark plugs for: - Deposits bridging spark plug gap (A). - Wet black deposits (oil fouling) (B). - Dry black deposits (carbon fouling) (C). - Overheating (D). - Deposits fused on spark plug (E). - Pre-ignition damage (F). - Normal spark plug (G). 5. Adjust the spark plug as required. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1479 INSTALLATION 1. Install the LH spark plugs. 2. Install the RH spark plugs. 3. Install the COPs. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Pressure Limit Chart Compression Pressure Limit Chart The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1483 Compression Check: Testing and Inspection 1. Make sure the oil in the crankcase is of the correct viscosity and at the proper level and that the battery is properly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all the spark plugs. 2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the Compression Tester in the No. 1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, and using the auxiliary starter switch, crank the engine a minimum of five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Compression Pressure Limit Chart Compression Pressure Limit Chart The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. If one or more cylinders reads low, squirt approximately one tablespoon of Super Premium SAE 5W30 Motor Oil, X0-5W30-QSP meeting Ford specification WSS-M2C153-G on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. - If compression improves considerably, piston rings are faulty. - If compression does not improve, valves are sticking or seating improperly. - If two adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer does not indicate whether this vehicle has adjustable or non-adjustable valves. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications Drive Belt: Specifications Drive Belt Number Of Ribs 8 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Locations > With Air Conditioning Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Locations > With Air Conditioning > Page 1492 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Locations > Page 1493 Drive Belt: Description and Operation The accessory drive consists of the: drive belt. - generator pulley. - power steering pump pulley. - crankshaft vibration damper and pulley. - A/C clutch pulley (if equipped). - belt idler pulley. - drive belt tensioner. - water pump pulley. The accessory drive: has a single serpentine drive belt. The 4.2L engine drive belt has six ribs. - The 4.6L, and 5.4L engine drive belts have eight ribs. - has automatic tensioning. - is not adjustable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Drive Belt: Initial Inspection and Diagnostic Overview 1. Verify the concern by running the engine. V-Ribbed Belt With Cracks (Acceptable) V-Ribbed Belt With Chunks Of Rib Missing (Not Acceptable) 2. Inspect the drive belt for chunking, fraying and wear. Refer to the illustrations. 3. Check the drive belt for correct routing. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1496 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1497 Drive Belt: Component Tests and General Diagnostics Belt Tensioner NOTE: Tensioners are shown in free-state position against arm travel stops. 4.6L, 5.4L Drive Belt Tensioner/Belt Length Indicator With A/C Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1498 4.6L, 5.4L Belt, Drive Tensioner/Belt Length Indicator Without A/C Automatic tensioners are calibrated at the factory to provide the correct amount of tension to the belt. Unless a spring within the tensioner assembly breaks or some other mechanical part of the tensioner fails, there is no need to check tensioners for proper tension. The only mechanical check that need be made, if you have any doubt about the tensioner function, would be to remove the belt in the area of the tensioner, to avoid belt contact, then using the proper tool, rotate the tensioner from its relaxed position through its full stroke and back to the relaxed position to assure that there is no "stick, grab, bind," and to assure that there is tension on the spring. It is a normal condition for the tensioner to be moving, under certain conditions, when the engine is running. If the tensioner meets these criteria, it should be assumed to be a good tensioner. Drive Belt Misalignment CAUTION: Incorrect drive belt installation will cause excessive drive belt wear and may cause the drive belt to come off the drive pulleys. Non-standard replacement drive belts may track differently or improperly. If a replacement drive belt tracks improperly, replace it with an original equipment drive belt to avoid performance failure or loss of belt. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1499 With the engine running, check drive belt tracking. If the (A) edge of the drive belt rides beyond the edge of the pulleys, noise and premature wear may occur. Make sure the (B) drive belt rides correctly on the pulley. If a drive belt tracking condition exists, proceed with the following: Visually check the drive belt tensioner for damage, especially the mounting pad surface. If the drive belt tensioner is not installed correctly, the mounting surface pad will be out of position. This will result in chirp and squeal noises. With the engine running, visually observe the grooves in the pulleys (not the pulley flanges or pulley front surfaces) for excessive wobble. Replace components as required. - Check all accessories, mounting brackets and the drive belt tensioner for any interference that would prevent the component from mounting properly. Correct any interference condition and recheck belt tracking, - Tighten all accessories, mounting brackets, and drive belt tensioner retaining hardware to specification. Recheck the drive belt tracking. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > With A/C Drive Belt: Service and Repair With A/C Removal 1. Rotate the tensioner clockwise and remove the drive belt. Installation 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > With A/C > Page 1502 Drive Belt: Service and Repair Without A/C Removal 1. Rotate the tensioner counterclockwise and remove the drive belt. Installation 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair REMOVAL 1. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the shield. 2. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. 3. Disconnect the (A) Positive Crankcase Ventilation (PCV) hose and the (B) Idle Air Control (IAC) valve inlet tube. 4. Loosen the clamps and remove the air cleaner outlet tube and resonator. INSTALLATION 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 1508 CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. NOTE: The inlet air cleaner has an alignment tab which fits into a slot on the outlet air cleaner. Make sure the tabs are aligned correctly. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair REMOVAL 1. Open the (A) air cleaner clamp and set the (B) outlet Air Cleaner (ACL) aside. 2. Remove the (A) Air Cleaner (ACL) element from the (B) open end of inlet. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. NOTE: The inlet air cleaner has an alignment tab which fits into a slot on the outlet air cleaner. Make sure tabs are aligned correctly. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair Note: Not all of these vehicles were equipped with a Cabin Air Filter. Only vehicles with a filter cover in the location shown have a Cabin Air Filter Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Gauge Special Tool(s) WARNING - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the Schrader valve cap and install the Fuel Pressure Gauge. 2. Open the manual valve slowly on the Fuel Pressure Gauge and relieve the fuel pressure. - This will drain some fuel out of the system. Place the fuel in a suitable container. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications Oil Filter: Specifications Oil Filter 14-17 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 1531 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 1532 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 1538 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 1539 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Hose: > NHTSA98V192000 > Aug > 98 > Recall 98V192000: Speed Control Cable Loose Cruise Control Servo Cable: All Technical Service Bulletins Recall 98V192000: Speed Control Cable Loose Vehicle Description: Light duty pickup trucks. A speed control cable may not have fully seated into the accelerator bracket at time of installation. If the cable is not fully seated into this bracket, the cable could separate from the bracket. A loose cable can result in the throttle not fully returning to idle and cause an increase in stopping distance. Dealers will add a retaining clip to the speed control cable fitting at the accelerator bracket. Ford is notifying dealers on or about August 11, 1998. These vehicles have not yet been released for sale to the public. 1999 FORD TRUCK F150 1999 FORD TRUCK F250 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins > Page 1550 Heater Hose: Specifications Hose Clamp ......................................................................................................................................... .......................................... 1.6-2.2 N.m (17-22 Lb-In) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Hose Couplings Heater Hose: Service and Repair Heater Hose Couplings Heater Hose Disconnect Tool SPECIAL TOOL(S) DISCONNECT 1. Depressurize the engine cooling system. WARNING: THE ENGINE MUST BE OFF, FULLY COOL AND THE COOLING SYSTEM FULLY DEPRESSURIZED BEFORE ATTEMPTING TO DISCONNECT ANY HEATER WATER HOSES. FAILURE TO COMPLY WITH THIS WARNING CAN RESULT IN SERIOUS INJURY OR BURNS FROM HOT LIQUID ESCAPING OUT OF THE ENGINE COOLING SYSTEM. 2. Push the heater water hose toward the tube to fully expose the locking tabs. 3. Push the Heater Hose Disconnect Tool over the coupling retainer windows to compress the retainer locking tabs. NOTE: When compressing the white coupling retainer, the Heater Hose Disconnect Tool must be perpendicular to and on the highest point of the coupling. 4. Pull the heater water hose away from the heater core tube. NOTE: A slight twisting motion while pulling on the heater water hose may be necessary to assist in the removal. 5. Plug the heater water hose. 6. Remove the white coupling retainer from the tube. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Hose Couplings > Page 1553 7. Spread the retainer tabs apart and slide the retainer off the tube. 8. Discard the retainer. CONNECT 1. Clean the tubes and lubricate with Ford Rubber Suspension Insulator Lube E25Y-19553-A or equivalent meeting Ford specification ESF-M99B112-A. 2. Install a new coupling retainer, spacer, and lubricated O-rings into the quick disconnect coupling housing. 3. Push the heater water hose with a quick disconnect coupling onto the tube. 4. Make sure the coupling is fully engaged by lightly pulling on the heater water hose. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Hose Couplings > Page 1554 Heater Hose: Service and Repair Removal and Installation REMOVAL 1. Drain the cooling system. 2. Disconnect the heater outlet hose at the engine. 3. Disconnect the heater inlet hose at the engine. 1 Loosen the hose clamp. 2 Disconnect the heater inlet hose. 4. Compress the holding tabs and disconnect the heater water hoses at the heater core. INSTALLATION 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications Hose/Line HVAC: Specifications Tube Bracket Nut ................................................................................................................................. ............................................. 10-14 N.m (8-10 Lb-Ft) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications > Page 1558 Hose/Line HVAC: Description and Operation NOTE: Replacement of the suction accumulator/drier is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator/drier. The condenser to evaporator tube contains high pressure liquid refrigerant upstream of the A/C evaporator core orifice. The A/C manifold and tube is attached to the A/C compressor with the O-ring seals and has the following features: - The upstream side contains low pressure refrigerant gas. - The downstream side contains high pressure refrigerant gas. - An integral non-serviceable muffler and a serviceable high pressure A/C charge port valve are located on the downstream side. - The downstream side also contains a fitting used to mount the A/C pressure cut-off switch. A long-travel Scharder-type valve stem core is installed in the fitting so that the A/C pressure cut-off switch can be removed without discharging the A/C system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications > Page 1559 Hose/Line HVAC: Service and Repair REMOVAL 1. Remove the battery and the battery tray. 2. Recover the refrigerant. See: Heating and Air Conditioning/Service and Repair/Refrigerant Recovery 3. Disconnect the condenser to evaporator line spring lock coupling from the A/C evaporator core. 4. Disconnect the condenser lower fitting. NOTE: Use a backup wrench to hold the line during disconnection to prevent damage to the condenser to evaporator line. 5. Remove the line bracket nut. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications > Page 1560 6. Remove the suction accumulator/drier bracket clamp bolt. 7. Remove the condenser to evaporator line. INSTALLATION 1. Follow the removal procedure in reverse order. - Lubricate the O-ring seal with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications TORQUE SPECIFICATIONS Pressure Hose Fitting .............................................................................................................................................................. 17-23 Nm (12.6-17 ft. lbs.) Return Hose Fitting ................................................................................... .............................................................................. 17-23 Nm (12.6-17 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications > Page 1564 Power Steering Line/Hose: Service and Repair Special Tools Removal 1. Refer to the System View illustration for the hose routing and retention points. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications > Page 1565 Installation 1. When connecting a fitting with a seal ring, the ring must be replaced. The Seal Replacer is used to install the return line connector seal and the pressure line connector seal. 2. Fill and leak check the system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications > Page 1566 Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Hoses (Lower) Radiator Hose: Service and Repair Radiator Hoses (Lower) Removal 1. Partially drain the cooling system. 2. Remove the outlet side of the air cleaner assembly. 3. Disconnect the lower radiator hose from the water pump. 4. Disconnect the lower radiator hose from the degas bottle. 5. Raise and support the vehicle. 6. Disconnect the lower radiator hose connections from the oil cooler. 7. Disconnect the lower radiator hose from the radiator. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Hoses (Lower) > Page 1571 8. Lower the vehicle. 9. Remove the lower radiator hose. Installation 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Radiator Hoses (Lower) > Page 1572 Radiator Hose: Service and Repair Radiator Hoses (Upper) Removal 1. Partially drain the cooling system. 2. Remove the upper radiator hose. 1 Release the hose clamps and slide them away from the hose ends. 2 Remove the upper radiator hose. Installation 1. Install the upper radiator hose. 1 Position the upper radiator hose. 2 Position and secure the hose clamps. 2. Fill the cooling system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Hydraulic brake fluid color must conform with the requirements of Federal Motor Vehicle Safety Standard 116. Under this standard, brake fluids are visually different from other automotive fluids such as transmission, power steering and engine oil. High Performance DOT3 Brake Fluid Ford Specification ESA-M6C25-A Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Service Precautions > Technician Safety Information Brake Fluid: Technician Safety Information SAFETY PRECAUTIONS WARNING: Brake fluid may be irritating to the skin or eyes. In case of contact, take the following actions: ^ Eye Contact - rinse eyes thoroughly with water. ^ Skin Contact - wash skin with soap and water. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Service Precautions > Technician Safety Information > Page 1579 Brake Fluid: Vehicle Damage Warnings WARNING: Brake fluid contains polyglycol. ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Clean, fresh Ford High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A is the only brake fluid that should be used in Ford vehicles. Do not reuse brake fluid drained or bled from the system. - Do not use brake fluid that has been stored in an open container. - Do not use contaminated brake fluid. - Do not mix different types of brake fluid. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Specifications Clutch Fluid: Specifications - Use Ford High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Service and Repair > Bleeding Clutch Master Cylinder Clutch Fluid: Service and Repair Bleeding - Clutch Master Cylinder 1. Install clutch master cylinder in a vise. NOTE: When bleeding a dry replacement clutch master cylinder, remove clutch master cylinder-to-clutch slave cylinder tubing from vehicle and install to new master cylinder. 2. Fill master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AA or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 3. Insert clutch slave cylinder end of tube in a waste container to prevent fluid from leaking. 4. Push the master cylinder push rod all the way in. While holding the push rod in, plug the end of the tube to prevent air from entering the tube and master cylinder. Perform this step several times until all air has been bled from the clutch master cylinder. NOTE: Be sure to keep clutch master cylinder reservoir full during this operation to prevent additional air from entering the master cylinder. 5. When all air is expelled from the clutch master cylinder (no bubbles come out of the tube), install the clutch master cylinder and tubing to the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Service and Repair > Bleeding Clutch Master Cylinder > Page 1585 Clutch Fluid: Service and Repair Bleeding - Clutch Slave Cylinder Clutch Hydraulic System Bleeding, Concentric Cylinder Clutch Slave 1. If bleeding a dry replacement clutch master cylinder, refer to Bench Bleed Procedure, Clutch Master Cylinder. See: Transmission and Drivetrain/Clutch/Clutch Hydraulic System/Clutch Master Cylinder/Service and Repair 2. Disconnect the coupling at the transmission with Coupling Disconnect Tool T88T-70522-A or equivalent by sliding the white plastic sleeve toward the clutch slave cylinder while applying a slight tug on the clutch tube. CAUTION: Make sure hydraulic tube connection is free of contamination prior to disconnecting it. 3. Remove cap and diaphragm and fill reservoir to the step with High Performance DOT 3 Brake Fluid C6AZ-19542-AA or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. CAUTION: - Clean dirt and grease from around the reservoir cap. - Brake fluid must be certified to DOT 3 specification. 4. Apply 10-15 pounds of pressure to clutch pedal. 5. Using a small screwdriver, press the internal mechanism of the male coupling to open the valve. While continuing to hold the valve open, slowly depress the clutch pedal to the floor and hold. 6. Remove the screwdriver from the coupling, closing the valve. 7. Release the clutch pedal. 8. Refill reservoir to level at step. CAUTION: The reservoir must be kept full at all times to make sure there will be no additional introduction of air into the system. 9. Repeat Steps 4 through 7. 10. Close reservoir. Reconnect the coupling to the clutch slave cylinder. Check that the connection is secure by applying a slight tug to the clutch tube. 11. Stroke the clutch pedal as rapidly as possible for five to ten strokes. 12. Wait one to three minutes. 13. Repeat Steps 11 and 12 three more times. 14. Loosen bleed screw (located in the slave cylinder body next to the inlet connection). 15. Depress and hold clutch pedal while tightening bleed screw 3-5 Nm (27-44 inch lbs.). 16. Refill the reservoir to level at step. 17. The hydraulic system should now be fully bled and should properly release the clutch. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations Coolant: Technical Service Bulletins Engine Coolant - Propylene Glycol Recommendations Article No. 01-23-6 11/26/01 ^ ENGINE COOLANT - PROPYLENE GLYCOL - FORD MOTOR COMPANY POSITION ON ENGINE COOLANTS MADE FROM PROPYLENE GLYCOL ^ ENGINE COOLANT - PROPYLENE GLYCOL-BASED - FORD MOTOR COMPANY POSITION ON PROPYLENE GLYCOL-BASED ENGINE COOLANTS FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2002 FOCUS 2002 THUNDERBIRD 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT 2000-2002 F-650, F-750 LINCOLN: 1989-1992 MARK VII 1989-2002 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1989-1994 TOPAZ 1989-1997 COUGAR 1989-2002 GRAND MARQUIS, SABLE 1991-1994 CAPRI 1991-1999 TRACER 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER MERKUR: 1989 SCORPIO, XR4TI This article is being republished in its entirety to update the model year coverage. ISSUE This TSB article describes Ford Motor Company's position on the use of propylene glycol-based engine coolants. ACTION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 1590 Ford Motor Company does not recommend nor endorse the use of engine coolants made with propylene glycol in Ford vehicles. Ford Motor Company currently recommends the use of ethylene glycol-based engine coolants. Published information suggests that engine coolants made with propylene glycol may provide engine cooling performance equivalent to engine coolants made with ethylene glycol. However, different brands of engine coolant provide varying corrosion protection for the cooling system. Ford does not have performance data for the multitude of engine coolants available in the aftermarket and therefore cannot recommend the use of any coolant except those sold by Ford Customer Service Division. Consult the vehicle's Owner's Guide to determine the appropriate Ford Customer Service Division coolant for the vehicle. Furthermore, claims of toxicological and environmental advantages of propylene glycol over ethylene glycol may be misleading. When significant new information is developed, Ford will review this policy. Ford Motor Company specifications recommend that vehicles be maintained using certain ethylene glycol-based engine coolants. Those specifications do not refer to engine coolants made with propylene glycol. Although the Ford New Vehicle Limited Warranty is not automatically voided upon the use of a coolant made with propylene glycol, if such use results in damage to the vehicle or its components, the cost of repairing the damage would not be covered by the Ford New Vehicle Limited Warranty. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-16-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity 19.4 qts .............................................................................................................................................................. ....................................... Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1593 Coolant: Fluid Type Specifications Coolant Type ....................................................................................................................................... ................................ Ford Premium Engine Coolant Ford Specification................................................................................................................................. .........................................................ESE-M97B44-A Note: Use Ford Premium Engine Coolant (green in color). DO NOT USE Ford Extended LIfe Engine Coolant (orange in color). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Page 1594 Coolant: Service Precautions DO NOT mix green colored coolant with orange colored coolant. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage Fluid - A/T: Technical Service Bulletins A/T - Mercon V ATF Usage TSB 06-14-4 07/24/06 MERCON ATF IS BEING REPLACED BY MERCON V ATF AS A SERVICE FLUID. FORD: 1980-1997 Crown Victoria 1981-1997 Mustang, Thunderbird 1981-2003 Escort 1986-1993 Festiva 1986-1997 Taurus 1989-1997 Probe 1994-1997 Aspire 1995-2000 Contour 1980-1996 Bronco 1981-2003 F-150 1981-2004 E-Series, F-Super Duty 1983-1996 Ranger 1986-1996 Aerostar 1991-1997 Explorer 1993-2004 F-53 Motorhome Chassis 1995-1998 Windstar 1997-2004 Expedition 2000-2005 Excursion 2001-2007 Escape 1987-2000 F-B-Series 2000-2007 F-650, F-750 LINCOLN: 1980-1997 Town Car 1981-1997 Continental 1993-1997 Mark VIII 1998-2004 Navigator 2002-2003 Blackwood MERCURY: 1980-1997 Grand Marquis 1981-1997 Cougar 1986-1997 Sable 1987-1999 Tracer 1995-2000 Mystique 1999-2002 Cougar 1993-2002 Villager 1997 Mountaineer 2005-2007 Mariner MERKUR: 1985-1989 XR4TI This article supersedes TSB 01-15-7 to update the vehicle application chart. ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid. ACTION Beginning immediately all automatic transmission / transaxle applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will only continue for however long it takes to deplete what remains in inventory. SERVICE PROCEDURE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage > Page 1599 Service automatic transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V For proper fluid application on current and past model vehicles equipped with automatic transmissions I transaxles refer to the fluid usage chart. (Figure 1) CAUTION AUTOMATIC TRANSMISSIONS / TRANSAXLES THAT REQUIRE MERCON® V SHOULD STILL ONLY USE MERCON(R) V OR DUAL USAGE FLUID LABELED MERCON(R) / MERCON(R) V. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage > Page 1600 CAUTION MERCON(R) SP, MOTORCRAFT PREMIUM AUTOMATIC TRANSMISSION FLUID AND MOTORCRAFT M5 ATFS ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS RECOMMENDING THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR TRANSMISSION DAMAGE. CAUTION THE FUNCTIONAL CHARACTERISTICS OF FLUIDS FOR CVT TRANSMISSIONS ARE VERY DIFFERENT THAN THOSE OF OTHER AUTOMATIC TRANSMISSION FLUIDS (ATFS). USE OF A FLUID OTHER THAN MOTORCRAFT CONTINUOUSLY VARIABLE CHAIN TYPE TRANSMISSION FLUID OR ONE LABELED AS MEETING MERCON(R) C WILL CAUSE FUNCTIONALITY CONCERNS AND INTERNAL TRANSMISSION DAMAGE. CAUTION DO NOT USE AUTOMATIC TRANSMISSION FLUID SUPPLEMENTS, ADDITIVES, TREATMENTS OR CLEANING AGENTS. Parts Block WARRANTY STATUS: Information Only Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications A/T Fluid 4R100 .................................................................................................................................................. .......................................................... 15.5L (16.4 Qt) 4R70W ................................................................................................................................................. ......................................................... 13.1L (13.8 Qt) NOTE: Approximate dry fill capacity. Fluid level should be set by indicator on dipstick's normal operating range. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1603 Fluid - A/T: Fluid Type Specifications MERCON(R) automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4. Automatic (4R70W) ............................................................................................ ...................................................................................... MERCON V ATF Automatic (4R100) ................ MERCON(R) automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1604 Fluid - A/T: Diagrams PARK Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1605 PARK Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1606 PARK Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1607 PARK Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1608 2 ND GEAR Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1609 2 ND GEAR Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1610 TCC RELEASE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1611 TCC RELEASE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1612 LINE/SRV PRESSURE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1613 PARK NON-PTO Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1614 PARK NON-PTO Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1615 1ST GEAR NON-PTO Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1616 2ND GEAR NON-PTO Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1617 3RD GEAR NON-PTO Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1618 4TH GEAR NON-PTO Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1619 MANUAL 3RD GEAR NON-PTO Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1620 MANUAL 2ND GEAR NON-PTO Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1621 MANUAL 1ST GEAR NON-PTO Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1622 Fluid - A/T: Service Precautions DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission damage may occur. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1623 Fluid - A/T: Description and Operation 1. Normal maintenance requires periodic automatic transmission fluid changes. If a major service, such as a clutch, band, bearing, etc., is required, the automatic transmission fluid will also have to be removed for service. At this time, the torque converter, transmission cooler, cooler inlet tube and cooler tube must be thoroughly flushed to remove any dirt. When used under continuous or severe conditions, the transmission and torque converter should be drained and refilled with fluid. Normal Maintenance No recommended changes - Special Operating Conditions Change fluid at 48,000 kin (30,000 miles) 2. CAUTION: Use of a fluid other than specified could result in transmission malfunction and/or failure. Refer to the vehicle certification label affixed to the LH front door lock face panel or door pillar for the transmission code. 3. When filling a dry transmission and torque converter, refer to Specification. Check the fluid level. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 4R70W Fluid - A/T: Service and Repair 4R70W Removal 1. Raise and support vehicle. 2. Place a drain pan under the transmission fluid pan. 3. Drain transmission fluid, - Loosen the transmission fluid pan bolts and allow fluid to drain. After fluid is drained, remove the bolts. 4. Remove the (A) transmission fluid pan and (B) transmission fluid pan gasket. - Replace transmission fluid pan gasket as necessary. 5. Remove torque converter housing plug. 6. Remove the torque converter drain plug and drain the torque converter. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 4R70W > Page 1626 - Rotate the crankshaft to access the drain plug. 7. Clean and inspect the (A) transmission fluid pan, (B) transmission fluid pan gasket and (C) magnet. 8. Flush the fluid cooler, and fluid cooler lines. 9. Flush the torque converter. Installation 1. NOTE: A new torque converter drain plug must be used. Install the torque converter drain plug. 2. Install torque converter housing plug. 3. CAUTION: If installing a new filter, and the seal remains in the main control bore, carefully use a small screwdriver to remove the seal. Use care not to damage the main control bore. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 4R70W > Page 1627 NOTE: If the transmission is being repaired for a contamination-related failure, use a new filter and seal. The filter may be reused if no excessive contamination is present. Replace fluid filter and seal as required. 4. Position the (B) pan magnet into the (A) transmission fluid pan. 5. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage; if not damaged, the gasket should be reused. Install the transmission fluid pan and gasket. 1 Install the transmission fluid pan gasket. 2 Install the transmission fluid pan. 6. Install the bolts. 7. Lower the vehicle. 8. NOTE: When filling a dry transmission and torque converter start with a minimum of 4.7 liters (5 quarts). Fill transmission to proper fluid level. Use MERCON V Automatic Transmission Fluid or equivalent meeting MERCON V specification XT-5-QM. MERCON(R) automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 4R70W > Page 1628 Fluid - A/T: Service and Repair 4R100 Removal 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Remove the drain plug to allow the fluid to drain. 4. CAUTION: When replacing the transmission fluid and filter and seal assembly, the torque converter should be drained. The transmission cooler, cooler lines, and cooler bypass valve must be thoroughly flushed to remove any contamination. NOTE: Do not discard the gasket unless damaged. This is a reusable gasket. Remove the transmission fluid pan and gasket. 1 Loosen, but do not remove the bolts. 2 Remove the front and side bolts. 3 Lower the front of the fluid pan and allow the fluid to drain. 4 Remove the remaining fluid pan bolts and the fluid pan. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 4R70W > Page 1629 5. NOTE: After removal, discard the filter and seal assembly. Remove the filter and seal assembly by carefully pulling and rotating the filter as necessary. 6. CAUTION: Be careful not to scratch or damage the aluminum bore. The new seal may leak and damage to the case will result. If the seal remains in the pump bore, remove it carefully with a small screwdriver so as not to scratch or damage the aluminum bore. 7. Remove the torque converter drain plug cover. 8. Remove the torque converter drain plug. 9. NOTE: If equipped with a radiator in-tank transmission fluid cooler, auxiliary cooler, and an Oil-To-Air (OTA) cooler, the in-tank fluid cooler and the auxiliary cooler will need to be flushed, and the OTA will need to be replaced. NOTE: If performing the drain and refill procedure for maintenance the oil to air oil cooler will not need to be replaced. If performing an Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 4R70W > Page 1630 overhaul the Oil-To-Air Cooler (OTA) will be required to be replaced. Thoroughly flush the cooler lines, fluid coolers, and the cooler bypass valve. Installation 1. After the torque converter has drained, install the drain plug. 2. Install the torque converter drain plug cover. 3. NOTE: Prior to installation, lightly lubricate the seal with clean Motorcraft MERCON Multi-Purpose (ATF) Transmission Fluid XT-2-QDX or equivalent Meeting MERCON specification. MERCON(R) automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4. Press a new fluid filter and seal assembly into the pump bore until seated. 4. CAUTION: Mixing (A) 4x2-style and (B) 4x4-style transmission fluid filters and transmission pan assembly components can cause Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > 4R70W > Page 1631 transmission damage. Install filter assembly and transmission pan. 5. NOTE: Transmission pan gasket is reusable unless damaged. NOTE: Apply a light coat of petroleum jelly to hold the gasket to the fluid pan. Position the (A) gasket onto the cleaned fluid pan. Make sure the (B) magnet is positioned over the dimple in the fluid pan. 6. Install the fluid pan. 1 Position the fluid pan. 2 Install the bolts. 7. Lower the vehicle. 8. Reconnect the battery ground cable. 9. CAUTION: Use only Motorcraft MERCON Multi-Purpose (ATF) Transmission Fluid XT-2-QDX or equivalent Meeting MERCON specification. The use of any other fluids can result in the transmission failing to operate in a normal manner or failure. Refill the transmission. Add 6.2 liters (6.5 quarts) of Motorcraft MERCON Multi-Purpose(ATF) Transmission Fluid XT-2-QDX or equivalent Meeting MERCON specification. transmission fluid to the transmission through the fluid filler tube. - Start the engine. Move the transmission range selector lever through all the gear ranges and allow to engage before moving to the next gear. - Check and adjust the transmission fluid, in 0.24 liter (0.5 pint) increments, to the proper level (cross-hatched area of the fluid level indicator at normal operating temperature. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Page 1632 Special Tool Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > M/T - Mercon(R) V ATF Usage Information Fluid - M/T: Technical Service Bulletins M/T - Mercon(R) V ATF Usage Information TSB 06-26-1 01/08/07 MERCON ATF IS BEING REPLACED BY MERCON V AS A SERVICE FLUID FOR SOME MANUAL TRANSMISSIONS FORD: 1981-2003 Escort 1984-1995 Thunderbird 1985-2007 Mustang 1985-1996 Bronco 1985-2007 Ranger 1986-1997 Aerostar 1991-2004 Explorer 1995-2007 F-150 1996-2007 F-Super Duty 2001-2003 Explorer Sport Trac, Explorer Sport LINCOLN: 2001-2002 Lincoln LS MERCURY: 1984-1995 Cougar 1987-1999 Tracer ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as the service fluid for manual transmissions originally requiring MERCON(R). ACTION Beginning immediately all manual transmission applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will continue until remaining inventory has been depleted. SERVICE PROCEDURE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > M/T - Mercon(R) V ATF Usage Information > Page 1637 Service manual transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON/MERCON(R) V. For proper fluid application on current and past model manual transmissions refer to the fluid usage chart. (Figure 1) WARNING FULL SYNTHETIC MANUAL TRANSMISSION FLUID (XT-M5-QS), SAE 75W-90 API GL-4 GEAR OIL (XY-75W90-QGL) AND SAE 75W-90 PREMIUM SYNTHETIC TRANSAXLE LUBRICANT (XT-75W90-QGT) ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS RECOMMENDING THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > M/T - Mercon(R) V ATF Usage Information > Page 1638 Parts Block WARRANTY STATUS: Information Only Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Capacity ............................................................................................................................................... .......................................................................... 1.9L Note; Fill to 1/4 to 9/16 inches below bottom of filler hole. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 1641 Fluid - M/T: Fluid Type Specifications MERCON (r) ATF ................................................................................................................................ ............................................................... XT-2-QDX MERCON(R) automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Page 1642 Fluid - M/T: Service Precautions DO NOT over fill transmission beyond normal capacity. This may cause fluid foaming and transmission damage. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Front Front Axle Fluid Capacity Capacity ............................................................................................................................................... ............................................................ 3.5 - 3.7 Pints 3/8 inch below the bottom of fill hole. Rear Differential Fluid Capacity Capacity ............................................................................................................................................... .................................................................. 2.6 - 2.7L Fill no higher than 1/4 to 9/16 inch below fill plug. For complete fill of 8.8 and 9.75 Traction-Lok axles add 4 oz. of friction modifier C8AZ-19B956-A. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 1647 Fluid - Differential: Fluid Type Specifications Front Axle ............................................................................................................................................ ............................................................. SAE 75W-90 Rear Axle ............................................................................................................................................. .......................................... SAE 75W-140 Synthetic Note: The rear axle is filled with a synthetic axle lubricant and is considered lubricated for life. These lubricants do not need to be checked nor changed unless a leak is suspected, service is required, or the axle has been submerged in water. The axle lubricant should be changed any time the axle has been submerged in water. Add 4 ounces of friction modifier additive C8AZ-19B546-A, Ford specification EST-M2C118A for complete refill of Traction-Lok axles. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Page 1648 Fluid - Differential: Service Precautions DO NOT over fill differential beyond normal fluid level. Fluid foaming and damage may occur. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications Capacity Transfer Case Fluid ............................................................................................................................. ...................................................................... 2.0 Qts Note: Fill to bottom of fill hole. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 1653 Fluid - Transfer Case: Fluid Type Specifications Transfer Case Fluid ............................................................................................................................. ............................................................ Mercon ATF. MERCON(R) automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Page 1654 Fluid - Transfer Case: Service Precautions DO NOT over fill transfer case beyond normal fluid level. Fluid foaming and damage may occur. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Page 1655 Fluid - Transfer Case: Service and Repair FLUID FILL 1. CAUTION: If the proper fill procedures are not followed, transfer case failure can result. NOTE: The fluid level should be just below the fill plug. Remove the fill plug from the rear of the transfer case and check the fill level. If the fluid is below the specified level, fill with Motorcraft MERCON Multi-Purpose Automatic Transmission Fluid XT-2-QDX or -DDX or equivalent MERCON fluid. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications Technical Service Bulletin # 02-1-9 Date: 020121 Engine Oil - Oil Recommendations/Applications Article No. 02-1-9 01/21/02 ENGINE - ENGINE OIL - RECOMMENDED APPLICATIONS FOR SAE 5W-20 AND SAE 5W-30 MOTOR OILS - GASOLINE AND FLEXIBLE FUEL VEHICLES ONLY FORD: 1992-2002 CROWN VICTORIA 1993-1994 TEMPO 1993-1997 THUNDERBIRD 1993-2002 ESCORT, MUSTANG, TAURUS 1995-2000 CONTOUR 1998-2002 ESCORT ZX2 2000-2002 FOCUS 1993-1996 BRONCO 1993-1997 AEROSTAR 1993-2002 E SERIES, F-150, RANGER 1995-2002 WINDSTAR 1997-1999 F-250 LD 1997-2001 EXPLORER 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2000-2002 EXCURSION 2001-2002 ESCAPE LINCOLN: 1991-2002 TOWN CAR 1993-1998 MARK VIII 1993-2002 CONTINENTAL 2000-2002 LS 1998-2002 NAVIGATOR MERCURY: 1992-2002 GRAND MARQUIS 1993-1994 TOPAZ 1993-1997 COUGAR 1993-1999 TRACER 1993-2002 SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1997-2001 MOUNTAINEER This article is being republished in its entirety to update the vehicle models, engines and years affected. NOTE PLEASE REFER TO THE VEHICLE APPLICATION LIST LATER IN THIS TSB FOR A COMPLETE LIST OF VEHICLES AFFECTED BY THIS TSB. ISSUE Ford Motor Company now recommends SAE 5W-20 viscosity grade for servicing most gasoline and flexible fueled vehicles. ACTION All 2001 and 2002 vehicles where SAE 5W-20 is specified should be serviced at the recommended oil change intervals using SAE 5W-20. This oil is an improved formulation to improve fuel economy. Testing has validated this viscosity grade can be used in many previous model year vehicles. It is recommended ALL vehicles on the following Vehicle Application Listing be service with SAE 5W-20. All 2001-2002 vehicles other than those listed in the "Exception 2001 Vehicles" or "Exception 2002 Vehicles" chart are being filled with SAE 5W-20 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 1660 motor oil at the factory and should also be serviced with SAE 5W-20 oil. Exception 2001 Vehicles Exception 2002 Vehicles NOTE IF VEHICLE IS NOT LISTED IN THIS APPLICATION, SAE 5W-30 OIL IS RECOMMENDED. REFER TO TSB 99-8-16. Parts Block OTHER APPLICABLE ARTICLES: 99-8-16 SUPERSEDES: 01-4-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 490000, 497000, 499000 Veh. App. Listing Approved For SAE 5W-20 Motor Oil ^ 1993-1996 1.9L Escort/Tracer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 1661 ^ 1995-2000 2.0L Zetec Contour/Mystique ^ 1999-2002 2.0L Cougar ^ 1997-2002 2.0L Escort/Tracer ^ 1998-2002 2.0L Escort ZX2 ^ 2000-2002 2.0L Focus ^ 2001-2002 2.0L Escape ^ 1993-1997 2.3L Ranger ^ 1993-1994 2.3L Mustang ^ 1993-1994 2.3L Tempo/Topaz ^ 1998-2001 2.5L Ranger ^ 1995-2000 2.5L Contour/Mystique ^ 1999-2002 2.5L Cougar ^ 2001-2002 3.0L 4V Escape ^ 1996-2001 3.0L 4V Taurus/Sable ^ 1993-2002 3.0L (Vulcan) Aerostar/Ranger, ^ Taurus/Sable (Flexible Fuel and Gas) ^ 1995-2000 3.0L (Vulcan) Windstar ^ 1993-1994 3.0L (Vulcan) Tempo/Topaz ^ 2000-2002 3.0L 4V Lincoln LS ^ 1995-2002 3.8L Windstar ^ 1993-1997 3.8L Taurus/Sable, ^ Thunderbird/Cougar, Continental ^ 1994-2002 3.8L Mustang ^ 2002-2002 3.9L 4V Lincoln LS ^ 1997-2002 4.2L (SPI) F-150 (under 8500 GVW only), E-Series ^ 1996-2002 4.6L 2V Mustang ^ 1992-2002 4.6L Crown Victoria/Grand Marquis ^ 1991-2002 4.6L Town Car ^ 1994-1997 4.6L 2V Thunderbird/Cougar ^ 1996-2002 4.6L 4V Mustang Cobra ^ 1995-2002 4.6L 4V Continental ^ 1993-1998 4.6L 4V Mark VIII Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 1662 ^ 1997-2002 4.6L 2V Triton F-150/250 (under 8500 GVW only), E-Series, Expedition ^ 1993-1999 4.9L E-Series, F-Series ^ 1993-1995 5.0L Mustang/Mustang Cobra ^ 1993-1993 5.0L Thunderbird/Cougar ^ 1997-2001 5.0L Explorer/Mountaineer ^ 1993-1996 5.0L E-Series, F-Series, Bronco ^ 2000-2002 5.4L Excursion ^ 1998-2002 5.4L 2V/4V Navigator ^ 1997-2002 5.4L 2V F-1501250 (under 8500 GVW only), Expedition, E-Series, E-350 Chassis/RV/Cutaway ^ 1993-1997 5.8L F-Series, Bronco ^ 1993-1996 5.8L E-Series ^ 2000-2002 6.8L Excursion ^ 1997-2002 6.8L E-Series, E-350 Chassis/RV/Cutaway ^ 1999-2002 6.8L Super Duty F-Series 250 HD/350/450/550 Motorhome ^ 1993-1998 7.5L All Vehicles NOTE FOR 1993 THROUGH 1998 MODEL YEAR FFV USE XO-10W30-FFV. NOTE THE "EXCEPTION 2001-2002 VEHICLES" SHOULD BE SERVICED WITH SAE 5W-30 MOTOR OIL Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 1663 Engine Oil: Technical Service Bulletins Motor Oil - Viscosity Grade Recommendation Article No. 99-8-16 05/03/99 MOTOR OIL - SAE VISCOSITY GRADE RECOMMENDATION - SERVICE TIP FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-1999 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-1999 CONTOUR LINCOLN-MERCURY: 1989-1992 MARK VII 1989-1994 TOPAZ 1989-1997 COUGAR 1989-1999 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1991-1994 CAPRI 1994-1998 MARK VIII 1995-1999 MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-1999 ECONOLINE, F-150, F-250 LD, RANGER 1991-1999 EXPLORER 1993-1999 VILLAGER 1995-1999 WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE Ford Motor Company now recommends SAE 5W-30 viscosity grade for servicing any Ford gasoline-powered vehicle regardless of model year. ACTION When servicing any Ford gasoline-powered vehicle, use SAE 5W-30 viscosity grade motor oil. Refer to the following text for further details. Both SAE 10W-30 and SAE 5W-30 viscosity grade motor oils have been recommended in the past depending on vehicle model and model year. Tests have proven SAE 5W-30 viscosity grade motor oil provides the optimum protection and benefits for Ford gasoline engines. At both high and low ambient temperature conditions, SAE 5W-30 provides the best overall protection. It allows faster starts under cold ambient temperatures. SAE 5W-30 also provides approximately 1/2% increase in fuel economy over SAE 10W-30. SAE 5W-30 viscosity grade motor oils certified for gasoline engines by the American Petroleum Institute (API) should be used for all service procedures requiring replacement of the motor oil. PART NUMBER PART NAME XO-5W30-QSP 5W-30 Motorcraft Super Premium Motor Oil OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 490000, 499000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil A/T Models .......................................................................................................................................... ............................................................. 6.3L (6.7 Qt) M/T Models .......................................................................................................................................... ............................................................ 6.0L (6.4 Qt) NOTE: Listed capacities are approximate. Check fluid level after filling. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1666 Engine Oil: Fluid Type Specifications Engine Oil Type ................................................................................................................................... ............................................................... SAE 5W-20 NOTE: Refer to TSB# 02-1-9 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1667 Engine Oil: Service Precautions SAFETY PRECAUTIONS WARNING: Prolonged and repeated contact with used engine oil may cause skin cancer. Avoid prolonged and repeated contact with oils, particularly used engine oils. - Wear protective clothing, including impervious gloves where practicable. - Do not put oily rags in pockets. - Avoid contaminating clothes, particularly underpants, with oil. - Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regularly. - First Aid treatment should be obtained immediately for open cuts and wounds. - Use barrier creams, applying them before each work period, to help the removal of oil from the skin. - Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have been removed. - Do not use gasoline, kerosine, diesel fuel, gas oil, thinner or solvents for cleaning skin. - If skin disorders develop, obtain medical advice without delay. - Where practicable, degrease components prior to handling. - Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage Power Steering Fluid: Technical Service Bulletins Steering - Mercon V(R) Fluid Usage TSB 07-1-7 01/22/07 MERCON(R) ATF REPLACED BY MERCON(R) V AS A SERVICE FLUID FOR SOME POWER STEERING SYSTEMS FORD: 1996-1997 Thunderbird 1996-2007 Crown Victoria, Mustang, Taurus 1998-2003 Escort 2000-2007 Focus 2002-2005 Thunderbird 2005-2006 Ford GT 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1996-1997 Aerostar 1996-2007 E-Series, Explorer, Ranger 1997-2004 F-53 Motorhome Chassis 1997-2007 Expedition, F-150, F-Super Duty 1998-2003 Windstar 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2007 Escape 2004-2007 Freestar 2005-2007 Escape Hybrid 1996-1997 Cargo 1996-1998 L-Series 1996-1999 F- B-Series 2000-2007 F-650, F-750 2006-2007 Low Cab Forward LINCOLN: 1996-1998 Mark VIII 1996-1999 Continental 1996-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX MERCURY: 1996-1997 Cougar 1996-2005 Sable 1996-2007 Grand Marquis 1999-2002 Cougar 2003-2004 Marauder 2005-2007 Montego 2006-2007 Milan 1997-2007 Mountaineer 1998-2002 Villager 2004-2007 Monterey 2005-2007 Mariner Hybrid, Mariner ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid for power steering systems originally requiring MERCON(R). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage > Page 1672 ACTION Beginning immediately all power steering applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will continue until remaining inventory has been depleted. SERVICE PROCEDURE Service power steering Systems requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. CAUTION APPLICATIONS RECOMMENDING TYPE F AUTOMATIC TRANSMISSION AND POWER STEERING FLUID MUST CONTINUE TO USE THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE Parts Block WARRANTY STATUS: Information Only Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 1673 Power Steering Fluid: Specifications Use Motorcraft MERCON(r) Multi-Purpose ATF, XT-2-QDX or equivalent MERCON(r) approved fluid. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 1674 Power Steering Fluid: Service Precautions CAUTION: Use only manufacturer recommended Power Steering Fluid or system damage may result. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants Technical Service Bulletin # 99-19-6 Date: 990920 A/C - Identification of Non Approved Refrigerants Article No. 99-19-6 09/20/99 ^ AIR CONDITIONING - IDENTIFICATION OF NON-FORD APPROVED REFRIGERANTS ^ AIR CONDITIONING - PURGING AIR FROM SYSTEM FORD: 1985-1986 LTD 1985-1988 EXP 1985-1994 TEMPO 1985-1997 THUNDERBIRD 1985-2000 CROWN VICTORIA, ESCORT, MUSTANG 1986-2000 TAURUS 1988-1993 FESTIVA 1989-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2000 FOCUS 1985-1990 BRONCO II 1985-1996 BRONCO 1985-1997 F-250 HD, F-350 1985-2000 ECONOLINE, F-150, F-250 LD, RANGER 1986-1997 AEROSTAR 1988-1997 F SUPER DUTY 1991-2000 EXPLORER 1995-2000 WINDSTAR 1997-2000 EXPEDITION 1999-2000 SUPER DUTY F SERIES 1985-1991 CL-CLT-9000 SERIES 1985-1999 L SERIES 1985-2000 F & B SERIES 1986-1998 CARGO SERIES 1997-1998 AEROMAX, LOUISVILLE LINCOLN: 1985-1992 MARK VII 1985-2000 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000 LS 1998-2000 NAVIGATOR MERCURY: 1985-1986 MARQUIS 1985-1987 LYNX 1985-1994 TOPAZ 1985-1997 COUGAR 1985-2000 GRAND MARQUIS 1986-2000 SABLE 1987-1989 TRACER 1991-1994 CAPRI 1991-2000 TRACER 1995-2000 MYSTIQUE 1999-2000 COUGAR 1993-2000 VILLAGER 1997-2000 MOUNTAINEER MERKUR: 1985-1989 XR4TI 1988-1989 SCORPIO Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1679 This TSB article is being republished in its entirety to add model year vehicles ISSUE A number of non-approved/alternate refrigerants have entered the marketplace and are being advertised as "drop-in replacements" for R-12 and R-134a. The use of non-approved refrigerants such as R-22, hydrocarbons, and other refrigerant blends could cause safety, durability, and performance concerns if they are installed in Ford A/C systems. Identification of the type of refrigerant contained in vehicle A/C systems, before servicing, is necessary to prevent dealer service equipment and refrigerant supplies from being contaminated with non-approved refrigerants. ACTION Refrigerant identification must be performed prior to recovering the refrigerant into a recovery machine to prevent cross-contamination of the recovery machine and other A/C systems being serviced with that recovery machine. Refer to the following text. OTHER APPLICABLE ARTICLES: 94-14-3, 95-18-4 SUPERSEDES: 98-12-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1993-2000 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles OPERATION DESCRIPTION TIME 991906A Test A/C System For 0.3 Hr. Contaminated Refrigerant DEALER CODING CONDITION BASIC PART NO. CODE R-12 49 OASIS CODES: 208000, 208999 A/C Refrigerant Analyzer Function Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1680 Ford Motor Company has approved the Rotunda Deluxe A/C Refrigerant Analyzer (198-00003) for use on Ford and Lincoln-Mercury vehicles (Figure 1). The analyzer provides the technician with a quick and easy way to identify the type and percentage of refrigerant (R-134a, R-12, R-22, or flammable hydrocarbon). The analyzer can also provide the percentage of air in the A/C system and automatically purge air from the system. The A/C Refrigerant Analyzer is designed to identify vapor gas samples taken directly from automotive air conditioning systems or refrigerant storage cylinders. Refrigerant vapor passes through the multiple sensor Non-Dispersive Infra-Red (NDIR) sensing unit. The microprocessor calculates each refrigerant type and purity percentage which is displayed on the analyzer's Liquid Crystal Display (LCD). The analyzer identifies the purity percentage of R-134a, R-12, R-22, hydrocarbon; and air in the sample. If the purity percentage of the R-134a or R-12 is 98% or greater by weight, a green "PASS" Light Emitting Diode (LED) will light. If refrigerants R-134a or R-12 do not meet 98% purity levels, the red "FAIL" LED will light. Levels of R-22 and flammable hydrocarbons above 2% will light the red "FAIL" light. If a hydrocarbon is detected above 5%, both the "FAIL" light and "HYDROCARBON" light will illuminate and a horn will sound alerting the user of potential hazards. The percent of air contained in the sample will be displayed if the R-134a or R-12 content is 98% or above. The analyzer eliminates the effect of air Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1681 when determining the refrigerant sample content because air is not considered a contaminant although air can affect A/C system performance. Air will automatically be purged until a pure refrigerant with a less than 2% by weight air measurement is reached. Recovery of Contaminated Refrigerant If contaminated refrigerant is detected, DO NOT recover the refrigerant into your R-134a or R-12 recovery/recycling equipment. Take the following actions: 1. Repeat the test to verify contaminated refrigerant is present. 2. Advise the customer of the contaminated A/C system and any additional cost to repair the system. The customer may wish to return to the service facility which performed the last A/C service. 3. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant. This equipment must only be used to recover contaminated refrigerant to prevent the spread to other vehicles. As an alternative, contact an A/C service facility in your area which has the proper equipment for refrigerant recovery. Repairing A Contaminated A/C System Once the contaminated refrigerant is removed from the system it will be necessary to repair the system. Ford recommends that you do the following to be sure a quality repair is made: 1. Determine the cause of the failure. 2. Determine which parts will need to be replaced. 3. Flush the heat exchangers to remove any oil that may be degraded due to the contaminated refrigerant. 4. Install a new suction/accumulator. 5. Properly oil match the system to verify that the correct amount of clean refrigerant oil is present in the system. 6. Evacuate the system for 45 minutes. 7. Recharge the system, verify proper operation, and leak test. Disposal of Contaminated Refrigerant Disposal of contaminated refrigerant is a new process to the automotive industry Listed below are companies that will assist with disposal of contaminated refrigerant. Ford Motor Company has not evaluated the processes of the listed refrigerant disposal companies and is not endorsing or promoting their companies Business transactions are between the dealership and disposal companies. Disposal costs will vary between $3.00 and $5.00 per pound, plus the cost of round trip cylinder shipping. ^ Omega Refrigerant Reclamation ^ 5263 North Fourth St. ^ Irwindale, CA 91706 ^ (310) 698-0991 FAX: (310) 696-7908 ^ Full Cycle Global ^ 2966 Wireton ^ Blue Island, IL 60406 ^ (708) 388-8551 FAX: (708) 399-6550 ^ U.S. Refrigerant Reclaim, Inc. ^ 12420 North Green River Road ^ Evansville, IN 47711 ^ (800) 207-5931 FAX: (812) 867-1463 ^ Full Cycle Global ^ 343 South Airline Highway Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1682 ^ Gonzales, LA 70737 ^ (504) 644-5333 FAX: (504) 644-1609 ^ CFC Reclamation ^ 1321 Swift North ^ Kansas City, MO 64116 ^ (816) 471-2511 ^ Full Cycle Global ^ 550 James St. ^ Lakewood, NJ 08701 ^ (908) 370-3400 FAX: (908) 370-3088 ^ National Refrigerants, Inc. ^ 11401 Roosevelt Blvd. ^ Philadelphia, PA 19154 ^ (215) 698-6620 FAX: (215) 602-8205 ^ Gartech Refrigerant Reclamation ^ 2002 Platinum ^ Garland, TX 75042 ^ (214) 272-4070 FAX: (214) 272-6548 ^ Refrigerant Reclaim Services ^ 121 S. Norwood Dr. ^ Hurst, TX 76053-7807 ^ (817) 282-0022 FAX: (800) 831-6182 ^ Full Cycle Global ^ 2055 Silber, Suite 109 ^ Houston, TX 77055 ^ (713) 681-7370 FAX: (713) 681-9947 ^ Refrigerant Reclaim, Inc. ^ 122 Old Stage Coach Road ^ Dumfries, VA 22026 ^ (800) 238-5902 FAX: (703) 441-0393 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Refrigerant Capacity ............................................................................................................................ ......................................................... 0.94 kg (33 oz) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1685 Refrigerant: Fluid Type Specifications Refrigerant............................................................................................................................................ ........................................................................R134a Ford Part Number ................................................................................................................................ ..................................................................... YN-19 Ford Specification ................................................................................................................................ ................................................... WSH-M17B19-A Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Refrigerant Capacity ............................................................................................................................ ............................................................ 266 ml (9 oz) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1690 Refrigerant Oil: Fluid Type Specifications Refrigerant Oil...................................................................................................................................... ...Polyalkylene Glycol (PAG) Oil (R-134a Systems) Ford Part Number ........................................................................................................................................................... F7AZ-19589-AD (MC-YN-12C) Ford Specification ................................................................................................................................ .................................................. WSH-M1C231-B Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure Brake Bleeding: Service and Repair Caliper Bleeding Procedure 1. NOTE: It is not necessary to do a complete brake system bleed if only the disc brake caliper was disconnected. Place a box end wrench on the disc brake caliper bleeder screw. Attach a rubber drain tube to the disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3. Loosen the disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the disc brake caliper bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 4. Tighten the disc brake caliper bleeder screw. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 1695 Brake Bleeding: Service and Repair Manual Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or replacement, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 2. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 3. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 4. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 5. Tighten the RH rear bleeder screw. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 1696 6. Repeat Steps 2, 3, 4 and 5 for the LH rear bleeder screw. 7. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 8. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 9. Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH front disc brake caliper bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 10. Tighten the RH front disc brake caliper bleeder screw. 11. Repeat Steps 7, 8, 9 and 10 for the LH front disc brake caliper bleeder screw. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 1697 Brake Bleeding: Service and Repair Master Cylinder Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or installation of new components, air can enter the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. NOTE: When the brake master cylinder has been replaced or the system has been emptied, or partially emptied, it should be primed to prevent air from entering the system. 1. For in-vehicle priming, disconnect the brake lines. 2. For bench priming, mount the brake master cylinder in a vise. 3. Install short brake tubes with the ends submerged in the brake master cylinder reservoir, and fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 4. Have an assistant pump the brake pedal, or slowly depress the primary piston until clear fluid flows from both brake tubes, without air bubbles. 5. If the brake master cylinder has been primed at the bench, install it in the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 1698 6. Remove the short brake tubes, and install the brake outlet tubes. 7. Bleed each brake tube at the brake master cylinder as follows: 1 Have an assistant pump the brake pedal, and then hold firm pressure on the brake pedal. 2 Loosen the rear most brake tube fittings until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the brake tube fitting. 3 Repeat this operation until clear, bubble-free fluid comes out. 4 Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation at the front brake tube. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 1699 Brake Bleeding: Service and Repair Pressure Bleeding 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers of pressure bleeding equipment. Follow the instructions of the manufacturer when installing the adapter. Install the bleeder adapter to the brake master cylinder reservoir, and attach the bleeder tank hose to the fitting on the adapter. 3. NOTE: Bleed the longest line first. Make sure the bleeder tank contains enough specified brake fluid to complete the bleeding operation. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 4. Open the valve on the bleeder tank. 5. Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten the RH rear bleeder screw and remove the rubber hose. 6. Continue bleeding the rear of the system, going in order from the LH rear bleeder screw to the RH front disc brake caliper bleeder screw ending with the LH front disc brake caliper bleeder screw. 7. Close the bleeder tank valve. Remove the tank hose from the adapter, and remove the adapter. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 1700 Brake Bleeding: Service and Repair 4 Wheel Anti-Lock Brakes (4WABS) NOTE: This procedure only needs to be performed if the 4-Wheel Anti-Lock Brake (4WABS) Hydraulic Control Unit (HCU) has been replaced or if the HCU lines have been opened. 1. Clean all dirt from and remove the brake master cylinder filler cap, and fill the brake master cylinder reservoir with the specified brake fluid. 2. Connect a clear waste line to the RH rear bleeder screw and the other end in a container partially filled with recommended brake fluid. 3. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 4. Tighten the RH rear bleeder screw, and disconnect the waste line. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 1701 5. Repeat Steps 2, 3 and 4 for the LH rear bleeder screw, the RH front disc brake caliper bleeder screw, and the LH front disc brake caliper bleeder screw, in that order. 6. Connect the NGS DCL cable adapter into the vehicle Data Link Connector (DLC) under the dash, and follow the NGS instructions. 7. Repeat the system bleed procedure as outlined in Steps 1 through 5. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. - To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming Deactivation Procedure 1. Disconnect the battery ground cable. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the driver air bag module from the vehicle. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set an air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. 4. Connect an air bag simulator to the vehicle harness at the top of the steering column. 5. Disconnect the passenger air bag module electrical connector. 6. Connect an air bag simulator to the vehicle harness. 7. Reconnect the battery ground cable. Reactivation Procedure 1. Disconnect the battery ground cable. WARNING: The air bag simulators must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the air bag simulator from the vehicle harness connector at the top of the steering column. 4. Install the driver air bag module. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. 5. Remove the air bag simulator from the vehicle harness connector at the passenger air bag module. 6. Connect the passenger air bag module electrical connector. 7. Reconnect the battery ground cable. 8. Prove out the system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 1707 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist should be completed following diagnosis or repair of any air bag system concern. 1. Is the connector at the base of the steering column connected? ................................................................................................................................ [ ] 2. Are the air bag modules connected? ............................................................................................... .......................................................................... [ ] 3. Is the Restraints Control Module (RCM) connected? ............................................................................................................................................... [ ] 4. Is the vehicle battery connected? .................................................................................................... .......................................................................... [ ] Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions Circuit Breaker: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1713 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1714 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1715 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1716 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1717 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1718 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1719 Circuit Breaker: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1720 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1721 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1722 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1723 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1724 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 1725 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Battery Junction Box Fuse: Locations Battery Junction Box Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Battery Junction Box > Page 1730 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Battery Junction Box > Page 1731 Fuse: Locations Central Junction Box Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations > Battery Junction Box > Page 1732 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1735 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1736 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1737 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1738 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1739 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1740 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1741 Fuse: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1742 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1743 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1744 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1745 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1746 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 1747 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Battery Junction Box Fuse: Application and ID Battery Junction Box Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Battery Junction Box > Page 1750 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Battery Junction Box > Page 1751 Fuse: Application and ID Central Junction Box Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and ID > Battery Junction Box > Page 1752 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1757 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1758 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1759 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1760 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1761 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1762 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1763 Fuse Block: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1764 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1765 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1766 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1767 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1768 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1769 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1770 Fuse Block: Connector Views Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1771 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 1777 Relay Box: Diagrams Central Junction Box Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 1778 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 1779 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 1780 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 1781 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Description and Operation Maintenance Required Lamp/Indicator: Description and Operation SERVICE ENGINE SOON Your vehicle is equipped with a computer that monitors the engine's emission control system. This is commonly known as the On Board Diagnostic System (OBD II). This OBD II system protects the environment by ensuring that your vehicle continues to meet government emission standards. The OBD II system also assists the service technician in properly servicing your vehicle. The SERVICE ENGINE SOON indicator light illuminates when the ignition is first turned to the ON position to check the bulb. If it comes on after the engine is started, on of the engine's emission control systems may be malfunctioning. The light may illuminate without a driveability concern being noted. The vehicle will ususally be drivable and will not require towing. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Component Information > Description and Operation > Page 1786 Maintenance Required Lamp/Indicator: Service and Repair Solid SERVICE ENGINE SOON light This means that the On Board Diagnostic System (OBD II) has detected a malfunction. Temporary malfunctions may cause your SERVICE ENGINE SOON light to illuminate. Examples are: 1. The vehicle has run out of fuel. (The engine may misfire or run poorly.) 2. Poor fuel quality or water in the fuel. 3. The fuel cap may not have been properly installed and securely tightened. The temporary malfunctions can be corrected by filling the fuel tank with good quality fuel and/or properly installing and securely tightening the gas cap. After three driving cycles with out these or any other temporary malfunctions present, the SERVICE ENGINE SOON light should turn off. (A driving cycle consists of a cold engine start-up followed by mixed city/highway driving.) No additional vehicle service is required. Blinking SERVICE ENGINE SOON light Engine misfire is occurring which could cause damage to your catalytic converter. You should drive in a moderate fashion (avoid heavy acceleration and deceleration) and have your vehicle serviced at the first available opportunity. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection Malfunction Indicator Lamp: Testing and Inspection Refer to Instrument Panel/Testing and Inspection/Procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair NOTE : This vehicle is not equipped with an CHANGE OIL SOON or OIL CHANGE REQUIRED indicator. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Suspension Warning Indicator > Component Information > Description and Operation Suspension Warning Indicator: Description and Operation The CK SUSP indicator will be illuminated if the instrument cluster receives a ground signal from the air suspension control module. The air suspension indicator will prove out when the ignition switch is placed in the START position and then in the RUN position. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Suspension Warning Indicator > Component Information > Description and Operation > Page 1796 Suspension Warning Indicator: Testing and Inspection Refer to Instrument Panel/Testing and Inspection/Procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation Vehicle Lifting and Jacking JACKING WARNING - THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT DOWN PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. - DO NOT RUN THE ENGINE WHEN JACKING THE VEHICLE. THE WHEELS CONTACTING THE GROUND COULD CAUSE THE VEHICLE TO MOVE. - SUPPORT THE VEHICLE PRIOR TO PERFORMING ANY PROCEDURE REQUIRING THE VEHICLE TO BE JACKED OFF THE GROUND. - MAKE SURE THE JACK AND JACK STANDS ARE PROPERLY LOCATED TO PREVENT THE VEHICLE FROM FALLING. - WHEEL CHOCKS SHOULD BE USED TO PREVENT THE VEHICLE FROM ROLLING AND FALLING OFF THE JACK. CAUTION: Never use a halfshaft as a lifting point. Jacking Points - Front, 4x4 The jacking point is a raised boss located on the front suspension lower arm. Jacking Points - Front, 4x2 The jacking point is a flat portion on the frame indicated by the arrow cut out. The jacking point is located behind the front tire and wheel assembly. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 1801 Jacking Points - Rear CAUTION: Never use the differential housing as a lifting point. The rear jacking points are located on the rear axle. LIFTING WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRING WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE PROCEDURES. CAUTION: Damage to suspension, exhaust and steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle Lifting Points - Twin Post Hoist Locate the front hoist adapters and rear hoist adapters (top of frame arc) as indicated. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 1802 Vehicle Lifting: Service and Repair Vehicle Lifting and Jacking JACKING WARNING - THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT DOWN PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. - DO NOT RUN THE ENGINE WHEN JACKING THE VEHICLE. THE WHEELS CONTACTING THE GROUND COULD CAUSE THE VEHICLE TO MOVE. - SUPPORT THE VEHICLE PRIOR TO PERFORMING ANY PROCEDURE REQUIRING THE VEHICLE TO BE JACKED OFF THE GROUND. - MAKE SURE THE JACK AND JACK STANDS ARE PROPERLY LOCATED TO PREVENT THE VEHICLE FROM FALLING. - WHEEL CHOCKS SHOULD BE USED TO PREVENT THE VEHICLE FROM ROLLING AND FALLING OFF THE JACK. CAUTION: Never use a halfshaft as a lifting point. Jacking Points - Front, 4x4 The jacking point is a raised boss located on the front suspension lower arm. Jacking Points - Front, 4x2 The jacking point is a flat portion on the frame indicated by the arrow cut out. The jacking point is located behind the front tire and wheel assembly. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 1803 Jacking Points - Rear CAUTION: Never use the differential housing as a lifting point. The rear jacking points are located on the rear axle. LIFTING WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRING WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE PROCEDURES. CAUTION: Damage to suspension, exhaust and steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle Lifting Points - Twin Post Hoist Locate the front hoist adapters and rear hoist adapters (top of frame arc) as indicated. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01L07 > Dec > 01 > Recall - Supplementary Tire Label Installation Technical Service Bulletin # 01L07 Date: 011201 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01L07 > Dec > 01 > Recall - Supplementary Tire Label Installation > Page 1812 Attachment I - Administrative Information OASIS OASIS will not be activated for this program. PLEASE NOTE Correct all vehicles in stock before delivery. DEALER-OWNER CONTACT An owner list will not be provided. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Parts and Labor Information LABOR ALLOWANCES PARTS REQUIREMENTS Ordering Instructions for Additional Labels Supplemental Tire Information Labels for this program are being sent directly to owners of the affected vehicles. Additional labels may be ordered at no charge by calling the Special Service Support Center at 1-800-325-5621. Inform the operator you are calling in regard to Field Service Action 01L07. Be prepared to provide your name, address, dealer P & A code, and the number of labels you need. Attachment III - Technical Information SUPPLEMENTAL TIRE INFORMATION LABEL AFFECTED VEHICLES: CERTAIN 1999 MODEL YEAR F-150 4X4 MODELS EQUIPPED WITH HEAVY-DUTY SERVICE PACKAGE SERVICE PROCEDURE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01L07 > Dec > 01 > Recall - Supplementary Tire Label Installation > Page 1813 ^ Open the driver's door. ^ Locate the original vehicle certification label on the B-pillar below the latch striker. ^ Check the tire size and the tire air pressure specifications on the label. Tire size should be listed as P255/70R6SL. Front and rear tire air pressure should be listed as 32 PSI/220 kPa. Label On Your Vehicle Is Correct: If tire size and air pressures are listed correctly on the label, you do not need to do anything. You may discard the enclosed supplemental label. Label On Your Vehicle Is NOT Correct: If tire size and air pressures are not listed correctly, please attach the supplemental label as follows: 1. Clean the area below the vehicle certification label using isopropyl alcohol (commonly referred to as rubbing alcohol) and a clean rag. 2. Remove any non-permanent labels such as oil change labels, if necessary. If there are any other permanent labels in this location, clean an area large enough to allow for full adhesion. 3. Allow the area to dry completely. 4. Peel the backing off the new supplemental tire information label and install it as shown. See Figure 1. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01L07 > Dec > 01 > Recall - Supplementary Tire Label Installation > Page 1814 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01L07 > Dec > 01 > Recall - Supplementary Tire Label Installation > Page 1815 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > NHTSA99V039000 > Feb > 00 > Recall 99V039000: Tire and Rim Identification Label Tires: Recalls Recall 99V039000: Tire and Rim Identification Label Vehicle Description: 4x4 vehicles with Off Road and High FGAWR option packages, and 4x2 vehicles with Sport option package. The tire and rim identification information is incorrect on the certification labels for these vehicles. This does not meet the requirements of FMVSS No. 120, "Tire Selection and Rims for Motor Vehicles other than Passenger Cars. "If incorrect tire information is given, underrated tires could be placed on the truck causing excessive tire wear or, in extreme cases, possible tire blowouts. Owners will be provided with a revised label overlay. Owner notification began June 9, 1999. Owners who do not receive the free revised label within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1999 FORD TRUCK F150 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label Technical Service Bulletin # 99S03 Date: 990601 Recall - Wheels/Tires, Incorrect Certification Label 99S03 SAFETY RECALL Certain 1999 Model Year F-150 Trucks Safety Compliance Certification Label - Wheel and Tire Size Designation ^ Dealer Letter ^ Attachment I ^ Attachment II ^ Labor Allowances ^ Parts Ordering information ^ Attachment III ^ Technical Information ^ Customer Notification Letter Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label > Page 1824 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label > Page 1825 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct the affected vehicles returned to your dealership, on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator (FDCC). Other eligible vehicles which are brought to your dealership. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS SUBMISSION Enter claims using DWE. See ACESII Manual, Sections 5 and 6. Attachment II - Labor and Parts Information Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label > Page 1826 LABOR ALLOWANCES PARTS REQUIREMENTS Safety Certification Partial Overlay Labels and installation instructions will be mailed to the vehicle owners. In addition, the owners will be notified that if they prefer, they may have the dealership personnel install the label at no charge. Labels and instructions for vehicles not reported as sold will be included in the Ford Dealership Consolidated Communicator (FDCC). If the customer no longer has the label, call the Recall Hotline (1-800-325-5621). When calling this number to order labels and instructions, be prepared to give the recall number 99S03. Attachment III - Technical Information IMPORTANT NOTICE TO OWNERS OF TWO (2) OR MORE F-150 TRUCKS The Safety Certification Label is matched to the Vehicle Identification Number (VIN) for each letter. To make sure that the correct label is attached to the correct vehicle, do not separate the Safety Certification Labels from the letters until you are ready to attach the label to the truck. INSTRUCTIONS FOR ATTACHING THE LABEL 1. Open the driver's door and locate the "Safety Certification Label", on the "B" pillar at the door opening. See Figure 1. 2. Verify that the VIN on the letter is the same as the VIN on the vehicle. NOTE: The vehicle VIN is located in two places: a) behind the left lower corner of the windshield and b) on the driver's door "B" pillar Safety Certification Label. 3. Clean the label and surrounding area with the supplied Label Adhesive Cleaning Pad. 4. Remove the partial label from the letter and place it over the cleaned area so the partial label is directly over the upper portion of the label as illustrated by the unshaded area of Figure 1. Use care not to cover the other information on the existing label. Smooth out air bubbles with a clean cloth. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label > Page 1827 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label > Page 1828 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page 1834 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01L07 > Dec > 01 > Recall - Supplementary Tire Label Installation Technical Service Bulletin # 01L07 Date: 011201 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01L07 > Dec > 01 > Recall - Supplementary Tire Label Installation > Page 1839 Attachment I - Administrative Information OASIS OASIS will not be activated for this program. PLEASE NOTE Correct all vehicles in stock before delivery. DEALER-OWNER CONTACT An owner list will not be provided. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Parts and Labor Information LABOR ALLOWANCES PARTS REQUIREMENTS Ordering Instructions for Additional Labels Supplemental Tire Information Labels for this program are being sent directly to owners of the affected vehicles. Additional labels may be ordered at no charge by calling the Special Service Support Center at 1-800-325-5621. Inform the operator you are calling in regard to Field Service Action 01L07. Be prepared to provide your name, address, dealer P & A code, and the number of labels you need. Attachment III - Technical Information SUPPLEMENTAL TIRE INFORMATION LABEL AFFECTED VEHICLES: CERTAIN 1999 MODEL YEAR F-150 4X4 MODELS EQUIPPED WITH HEAVY-DUTY SERVICE PACKAGE SERVICE PROCEDURE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01L07 > Dec > 01 > Recall - Supplementary Tire Label Installation > Page 1840 ^ Open the driver's door. ^ Locate the original vehicle certification label on the B-pillar below the latch striker. ^ Check the tire size and the tire air pressure specifications on the label. Tire size should be listed as P255/70R6SL. Front and rear tire air pressure should be listed as 32 PSI/220 kPa. Label On Your Vehicle Is Correct: If tire size and air pressures are listed correctly on the label, you do not need to do anything. You may discard the enclosed supplemental label. Label On Your Vehicle Is NOT Correct: If tire size and air pressures are not listed correctly, please attach the supplemental label as follows: 1. Clean the area below the vehicle certification label using isopropyl alcohol (commonly referred to as rubbing alcohol) and a clean rag. 2. Remove any non-permanent labels such as oil change labels, if necessary. If there are any other permanent labels in this location, clean an area large enough to allow for full adhesion. 3. Allow the area to dry completely. 4. Peel the backing off the new supplemental tire information label and install it as shown. See Figure 1. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01L07 > Dec > 01 > Recall - Supplementary Tire Label Installation > Page 1841 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01L07 > Dec > 01 > Recall - Supplementary Tire Label Installation > Page 1842 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > NHTSA99V039000 > Feb > 00 > Recall 99V039000: Tire and Rim Identification Label Tires: All Technical Service Bulletins Recall 99V039000: Tire and Rim Identification Label Vehicle Description: 4x4 vehicles with Off Road and High FGAWR option packages, and 4x2 vehicles with Sport option package. The tire and rim identification information is incorrect on the certification labels for these vehicles. This does not meet the requirements of FMVSS No. 120, "Tire Selection and Rims for Motor Vehicles other than Passenger Cars. "If incorrect tire information is given, underrated tires could be placed on the truck causing excessive tire wear or, in extreme cases, possible tire blowouts. Owners will be provided with a revised label overlay. Owner notification began June 9, 1999. Owners who do not receive the free revised label within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1999 FORD TRUCK F150 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1851 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1852 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1853 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1854 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1855 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1856 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1857 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1858 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1859 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1860 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1861 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1862 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1863 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1864 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1865 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1866 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1867 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1868 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1869 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1870 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1871 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1872 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1873 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1874 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1875 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1876 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1877 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1878 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1879 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1880 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1881 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1882 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1883 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1884 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1885 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1886 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1887 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1888 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1889 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1890 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1891 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1892 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1893 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1894 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1895 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1896 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1897 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1898 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1899 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1900 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1901 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1902 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1903 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1904 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1905 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1906 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1907 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1908 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1909 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1910 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1911 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1912 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1913 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1914 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1915 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1916 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1917 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1918 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1919 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1920 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1921 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1922 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1923 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1924 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1925 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1926 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1927 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1928 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1929 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1930 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1931 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1932 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1933 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1934 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1935 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1936 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1937 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1938 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1939 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1940 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1941 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1942 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1943 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1944 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1945 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label Technical Service Bulletin # 99S03 Date: 990601 Recall - Wheels/Tires, Incorrect Certification Label 99S03 SAFETY RECALL Certain 1999 Model Year F-150 Trucks Safety Compliance Certification Label - Wheel and Tire Size Designation ^ Dealer Letter ^ Attachment I ^ Attachment II ^ Labor Allowances ^ Parts Ordering information ^ Attachment III ^ Technical Information ^ Customer Notification Letter Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label > Page 1950 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label > Page 1951 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct the affected vehicles returned to your dealership, on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator (FDCC). Other eligible vehicles which are brought to your dealership. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS SUBMISSION Enter claims using DWE. See ACESII Manual, Sections 5 and 6. Attachment II - Labor and Parts Information Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label > Page 1952 LABOR ALLOWANCES PARTS REQUIREMENTS Safety Certification Partial Overlay Labels and installation instructions will be mailed to the vehicle owners. In addition, the owners will be notified that if they prefer, they may have the dealership personnel install the label at no charge. Labels and instructions for vehicles not reported as sold will be included in the Ford Dealership Consolidated Communicator (FDCC). If the customer no longer has the label, call the Recall Hotline (1-800-325-5621). When calling this number to order labels and instructions, be prepared to give the recall number 99S03. Attachment III - Technical Information IMPORTANT NOTICE TO OWNERS OF TWO (2) OR MORE F-150 TRUCKS The Safety Certification Label is matched to the Vehicle Identification Number (VIN) for each letter. To make sure that the correct label is attached to the correct vehicle, do not separate the Safety Certification Labels from the letters until you are ready to attach the label to the truck. INSTRUCTIONS FOR ATTACHING THE LABEL 1. Open the driver's door and locate the "Safety Certification Label", on the "B" pillar at the door opening. See Figure 1. 2. Verify that the VIN on the letter is the same as the VIN on the vehicle. NOTE: The vehicle VIN is located in two places: a) behind the left lower corner of the windshield and b) on the driver's door "B" pillar Safety Certification Label. 3. Clean the label and surrounding area with the supplied Label Adhesive Cleaning Pad. 4. Remove the partial label from the letter and place it over the cleaned area so the partial label is directly over the upper portion of the label as illustrated by the unshaded area of Figure 1. Use care not to cover the other information on the existing label. Smooth out air bubbles with a clean cloth. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label > Page 1953 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label > Page 1954 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page 1960 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1965 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1966 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1967 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1968 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1969 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1970 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1971 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1972 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1973 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1974 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1975 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1976 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1977 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1978 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1979 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1980 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1981 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1982 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1983 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1984 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1985 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1986 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1987 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1988 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1989 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1990 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1991 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1992 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1993 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1994 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1995 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1996 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1997 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1998 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 1999 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2001 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2002 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2003 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2004 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2005 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2006 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2007 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2008 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2009 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2010 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2011 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2012 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2013 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2014 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2015 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2016 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2017 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2018 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2019 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2020 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2021 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2022 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2023 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2024 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2025 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2026 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2027 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2028 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2029 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2030 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2031 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2032 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2033 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2034 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2035 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2036 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2037 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2038 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2039 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2040 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2041 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2042 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2043 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2044 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2045 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2046 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2047 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2048 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2049 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2050 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2051 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2052 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2053 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2054 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2055 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2056 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2057 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2058 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2059 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Specifications > Mechanical Specifications Tires: Mechanical Specifications OPERATIONAL SPECIFICATIONS Tire Tread Depth LT245/75R16 A/S ................................................................................................................................ ....................................... 11.5 mm (0.45 inch) LT245/75R16 A/T ....................................................... ................................................................................................................ 12.9 mm (0.51 inch) P235/70R16 A/S .................................................................................................................................. ......................................... 9.1 mm (0.36 inch) P235/70R16 A/T ......................................................... ................................................................................................................. 10.4 mm (0.41 inch) P255/70R16 A/S .................................................................................................................................. .......................................... 9.4 mm (0.37 inch) P255/70R16 A/T ........................................................ .................................................................................................................. 10.7 mm (0.42 inch) P265/70R17 A/T .................................................................................................................................. ........................................ 10.9 mm (0.43 inch) P275/60R17 A/S ........................................................ .................................................................................................................... 9.1 mm (0.36 inch) Tire Runout .......................................................................................................................................... .............................................. 1.27 mm (0.05 inch) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Specifications > Mechanical Specifications > Page 2062 Tires: Pressure, Vacuum and Temperature Specifications Tire Inflation ................................................................................................................................... See Safety Certification Label On Driver Door Jamb Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Specifications > Page 2063 Tires: Service and Repair Removal 1. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and wheel bearings. NOTE: To avoid damage or scratching to the center cap, place facing up when removed. Loosen the lug nuts. 1. Remove the center cap. 2. With the weight of the vehicle on the wheels, loosen the lug nuts. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 3. Raise and support the vehicle. 4. Remove the wheel and tire assembly. 1. Remove the lug nuts. 2. Remove the wheel and tire assembly, using a side-to-side rocking motion. Installation 1. WARNING: When a wheel is installed, always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the lug nuts to loosen and the wheel to come off while the vehicle is in motion, causing loss of control. Clean the wheel hub mounting surface and wheel centering O-ring. 2. Install the tire and wheel assembly. 1. Inspect the wheel centering O-ring. Replace if damaged. 2. Position the tire and wheel assembly. 3. Install the lug nuts hand-tight, then lower the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Specifications > Page 2064 3. CAUTION: Failure to tighten the lug nuts in a star pattern can result in high brake disc runout, which will speed up the development of brake roughness, shudder and vibration. Tighten the lug nuts in sequence. 4. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Install the center cap. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Recalls: > NHTSA99V039000 > Feb > 00 > Recall 99V039000: Tire and Rim Identification Label Wheels: Recalls Recall 99V039000: Tire and Rim Identification Label Vehicle Description: 4x4 vehicles with Off Road and High FGAWR option packages, and 4x2 vehicles with Sport option package. The tire and rim identification information is incorrect on the certification labels for these vehicles. This does not meet the requirements of FMVSS No. 120, "Tire Selection and Rims for Motor Vehicles other than Passenger Cars. "If incorrect tire information is given, underrated tires could be placed on the truck causing excessive tire wear or, in extreme cases, possible tire blowouts. Owners will be provided with a revised label overlay. Owner notification began June 9, 1999. Owners who do not receive the free revised label within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1999 FORD TRUCK F150 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Recalls: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label Technical Service Bulletin # 99S03 Date: 990601 Recall - Wheels/Tires, Incorrect Certification Label 99S03 SAFETY RECALL Certain 1999 Model Year F-150 Trucks Safety Compliance Certification Label - Wheel and Tire Size Designation ^ Dealer Letter ^ Attachment I ^ Attachment II ^ Labor Allowances ^ Parts Ordering information ^ Attachment III ^ Technical Information ^ Customer Notification Letter Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Recalls: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label > Page 2077 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Recalls: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label > Page 2078 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct the affected vehicles returned to your dealership, on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator (FDCC). Other eligible vehicles which are brought to your dealership. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS SUBMISSION Enter claims using DWE. See ACESII Manual, Sections 5 and 6. Attachment II - Labor and Parts Information Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Recalls: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label > Page 2079 LABOR ALLOWANCES PARTS REQUIREMENTS Safety Certification Partial Overlay Labels and installation instructions will be mailed to the vehicle owners. In addition, the owners will be notified that if they prefer, they may have the dealership personnel install the label at no charge. Labels and instructions for vehicles not reported as sold will be included in the Ford Dealership Consolidated Communicator (FDCC). If the customer no longer has the label, call the Recall Hotline (1-800-325-5621). When calling this number to order labels and instructions, be prepared to give the recall number 99S03. Attachment III - Technical Information IMPORTANT NOTICE TO OWNERS OF TWO (2) OR MORE F-150 TRUCKS The Safety Certification Label is matched to the Vehicle Identification Number (VIN) for each letter. To make sure that the correct label is attached to the correct vehicle, do not separate the Safety Certification Labels from the letters until you are ready to attach the label to the truck. INSTRUCTIONS FOR ATTACHING THE LABEL 1. Open the driver's door and locate the "Safety Certification Label", on the "B" pillar at the door opening. See Figure 1. 2. Verify that the VIN on the letter is the same as the VIN on the vehicle. NOTE: The vehicle VIN is located in two places: a) behind the left lower corner of the windshield and b) on the driver's door "B" pillar Safety Certification Label. 3. Clean the label and surrounding area with the supplied Label Adhesive Cleaning Pad. 4. Remove the partial label from the letter and place it over the cleaned area so the partial label is directly over the upper portion of the label as illustrated by the unshaded area of Figure 1. Use care not to cover the other information on the existing label. Smooth out air bubbles with a clean cloth. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Recalls: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label > Page 2080 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Recalls: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label > Page 2081 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page 2087 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > NHTSA99V039000 > Feb > 00 > Recall 99V039000: Tire and Rim Identification Label Wheels: All Technical Service Bulletins Recall 99V039000: Tire and Rim Identification Label Vehicle Description: 4x4 vehicles with Off Road and High FGAWR option packages, and 4x2 vehicles with Sport option package. The tire and rim identification information is incorrect on the certification labels for these vehicles. This does not meet the requirements of FMVSS No. 120, "Tire Selection and Rims for Motor Vehicles other than Passenger Cars. "If incorrect tire information is given, underrated tires could be placed on the truck causing excessive tire wear or, in extreme cases, possible tire blowouts. Owners will be provided with a revised label overlay. Owner notification began June 9, 1999. Owners who do not receive the free revised label within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1999 FORD TRUCK F150 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2096 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2097 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2098 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2099 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2100 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2101 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2102 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2103 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2104 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2105 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2106 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2107 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2108 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2109 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2110 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2111 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2112 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2113 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2114 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2115 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2116 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2117 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2118 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2119 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2120 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2121 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2122 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2123 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2124 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2125 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2126 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2127 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2128 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2129 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2130 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2131 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2132 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2133 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2134 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2135 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2136 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2137 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2138 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2139 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2140 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2141 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2142 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2143 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2144 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2145 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2146 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2147 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2148 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2149 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2150 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2151 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2152 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2153 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2154 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2155 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2156 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2157 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2158 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2159 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2160 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2161 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2162 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2163 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2164 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2165 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2166 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2167 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2168 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2169 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2170 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2171 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2172 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2173 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2174 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2175 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2176 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2177 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2178 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2179 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2180 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2181 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2182 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2183 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2184 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2185 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2186 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2187 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2188 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2189 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2190 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label Technical Service Bulletin # 99S03 Date: 990601 Recall - Wheels/Tires, Incorrect Certification Label 99S03 SAFETY RECALL Certain 1999 Model Year F-150 Trucks Safety Compliance Certification Label - Wheel and Tire Size Designation ^ Dealer Letter ^ Attachment I ^ Attachment II ^ Labor Allowances ^ Parts Ordering information ^ Attachment III ^ Technical Information ^ Customer Notification Letter Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label > Page 2195 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label > Page 2196 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct the affected vehicles returned to your dealership, on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator (FDCC). Other eligible vehicles which are brought to your dealership. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS SUBMISSION Enter claims using DWE. See ACESII Manual, Sections 5 and 6. Attachment II - Labor and Parts Information Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label > Page 2197 LABOR ALLOWANCES PARTS REQUIREMENTS Safety Certification Partial Overlay Labels and installation instructions will be mailed to the vehicle owners. In addition, the owners will be notified that if they prefer, they may have the dealership personnel install the label at no charge. Labels and instructions for vehicles not reported as sold will be included in the Ford Dealership Consolidated Communicator (FDCC). If the customer no longer has the label, call the Recall Hotline (1-800-325-5621). When calling this number to order labels and instructions, be prepared to give the recall number 99S03. Attachment III - Technical Information IMPORTANT NOTICE TO OWNERS OF TWO (2) OR MORE F-150 TRUCKS The Safety Certification Label is matched to the Vehicle Identification Number (VIN) for each letter. To make sure that the correct label is attached to the correct vehicle, do not separate the Safety Certification Labels from the letters until you are ready to attach the label to the truck. INSTRUCTIONS FOR ATTACHING THE LABEL 1. Open the driver's door and locate the "Safety Certification Label", on the "B" pillar at the door opening. See Figure 1. 2. Verify that the VIN on the letter is the same as the VIN on the vehicle. NOTE: The vehicle VIN is located in two places: a) behind the left lower corner of the windshield and b) on the driver's door "B" pillar Safety Certification Label. 3. Clean the label and surrounding area with the supplied Label Adhesive Cleaning Pad. 4. Remove the partial label from the letter and place it over the cleaned area so the partial label is directly over the upper portion of the label as illustrated by the unshaded area of Figure 1. Use care not to cover the other information on the existing label. Smooth out air bubbles with a clean cloth. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label > Page 2198 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label > Page 2199 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page 2205 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2210 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2211 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2212 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2213 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2214 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2215 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2216 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2217 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2218 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2219 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2220 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2221 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2222 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2223 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2224 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2225 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2226 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2227 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2228 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2229 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2230 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2231 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2232 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2233 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2234 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2235 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2236 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2237 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2238 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2239 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2240 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2241 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2242 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2243 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2244 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2245 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2246 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2247 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2248 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2249 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2250 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2251 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2252 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2253 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2254 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2255 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2256 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2257 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2258 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2259 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2260 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2261 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2262 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2263 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2264 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2265 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2266 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2267 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2268 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2269 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2270 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2271 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2272 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2273 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2274 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2275 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2276 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2277 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2278 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2279 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2280 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2281 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2282 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2283 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2284 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2285 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2286 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2287 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2288 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2289 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2290 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2291 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2292 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2293 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2294 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2295 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2296 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2297 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2298 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2299 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2300 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2301 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2302 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2303 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 2304 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 2305 Wheels: Specifications OPERATIONAL SPECIFICATIONS O-Ring .......................................................................................................................................................... 82 mm Diameter x 2.34 mm Square Section Wheel Stud And Lug Nuts .......................................................................................................................................................... M12 x 1.75 - 19 mm hex Max. Balance Weight (Total Of Inner & Outer Wheel Flanges) ......................................................................................................................... ...................................................... 170 g (6 oz) Cast Aluminum .................................................................................................................................... .................................................................. 17x7.5J Steel .................................................................... ...................................................................................................................................................... 16x7J Styled Aluminum ....................................................................................................................... ............................................................................... 16x7J Styled Argent Steel ................................... .............................................................................................................................................................. .. 16x7J Styled Chrome Steel .............................................................................................................. ................................................................................... 16x7J Wrought Aluminum ............................... .............................................................................................................................................................. ..... 16x7J Wheel Offset ....................................................................................................................... .................................................................................... 14 mm Wheel Rim Runout (Radial Or Lateral) ........................................................................................................................................... 1.12 mm (0.044 inch) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Leaks Wheels: Service and Repair Leaks 1. Forged aluminum wheels do not get pinhole leaks and should not be repaired using Aluminum Wheel Repair Compound. 2. Pinhole leaks in cast aluminum wheels compromise wheel integrity. Replace the wheel. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Leaks > Page 2308 Wheels: Service and Repair Replacement Removal 1. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and wheel bearings. NOTE: To avoid damage or scratching to the center cap, place facing up when removed. Loosen the lug nuts. 1. Remove the center cap. 2. With the weight of the vehicle on the wheels, loosen the lug nuts. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 3. Raise and support the vehicle. 4. Remove the wheel and tire assembly. 1. Remove the lug nuts. 2. Remove the wheel and tire assembly, using a side-to-side rocking motion. Installation 1. WARNING: When a wheel is installed, always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the lug nuts to loosen and the wheel to come off while the vehicle is in motion, causing loss of control. Clean the wheel hub mounting surface and wheel centering O-ring. 2. Install the tire and wheel assembly. 1. Inspect the wheel centering O-ring. Replace if damaged. 2. Position the tire and wheel assembly. 3. Install the lug nuts hand-tight, then lower the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Leaks > Page 2309 3. CAUTION: Failure to tighten the lug nuts in a star pattern can result in high brake disc runout, which will speed up the development of brake roughness, shudder and vibration. Tighten the lug nuts in sequence. 4. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Install the center cap. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2314 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2315 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2316 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2317 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2318 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2319 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2320 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2321 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2322 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2323 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2324 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2325 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2326 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2327 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2328 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2329 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2330 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2331 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2332 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2333 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2334 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2335 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2336 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2337 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2338 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2339 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2340 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2341 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2342 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2343 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2344 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2345 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2346 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2347 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2348 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2349 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2350 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2351 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2352 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2353 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2354 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2355 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2356 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2357 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2358 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2359 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2360 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2361 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2362 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2363 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2364 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2365 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2366 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2367 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2368 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2369 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2370 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2371 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2372 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2373 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2374 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2375 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2376 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2377 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2378 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2379 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2380 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2381 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2382 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2383 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2384 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2385 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2386 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2387 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2388 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2389 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2390 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2391 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2392 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2393 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2394 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2395 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2396 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2397 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2398 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2399 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2400 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2401 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2402 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2403 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2404 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2405 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2406 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2407 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2408 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Mechanical Specifications Wheel Bearing: Mechanical Specifications Maximum Axle Shaft End Play 0.762 mm Maximum Axle Shaft End Play 0.762 mm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Mechanical Specifications > Page 2411 Wheel Bearing: Fluid Type Specifications 8.8 Inch Ring Gear - Lubricate the new rear wheel bearing. Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. - Lubricate the lip of the new inner wheel bearing oil seal. Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 9.75 Inch Ring Gear - Lubricate the new rear wheel bearing. Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. - Lubricate the lip of the new inner wheel bearing oil seal. Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 2412 Wheel Bearing: Service Precautions CAUTION: Use only a grease that is recommended for wheel bearing applications. Use of the improper grease can cause bearing damage. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > 8.8-Inch Ring Gear Wheel Bearing: Service and Repair 8.8-Inch Ring Gear Special Tools Special Tools Removal 1. Remove the axle shaft. 2. NOTE: If the inner wheel bearing oil seal is leaking, the rear axle housing vent may be plugged. Using the special tools, remove the rear axle bearing and inner wheel bearing oil seal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > 8.8-Inch Ring Gear > Page 2415 Installation 1. Lubricate the new rear wheel bearing. - Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 2. Use the special tools to install the rear wheel bearing. 3. Lubricate the lip of the new inner wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tools, install the inner wheel bearing oil seal. 5. Install the axle shaft. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > 8.8-Inch Ring Gear > Page 2416 Wheel Bearing: Service and Repair 9.75-Inch Ring Gear Special Tools Special Tools Removal 1. Remove the axle shaft. 2. NOTE: If the inner wheel bearing oil seal is leaking, the rear axle housing vent may be plugged. Using the special tools, remove the rear wheel bearing and inner wheel bearing oil seal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > 8.8-Inch Ring Gear > Page 2417 Installation 1. Lubricate the new rear wheel bearing. - Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new inner wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tools, install the inner wheel bearing oil seal. 5. Install the axle shafts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Page 2418 Wheel Bearing: Tools and Equipment Special Tools Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications TORQUE SPECIFICATIONS Front Axle Hub Nut ........................................................................................................................................................... 255-345 Nm (188-254 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications TORQUE SPECIFICATIONS CAUTION: Failure to tighten the lug nuts in a star pattern can result in high brake disc runout, which will speed up the development of brake roughness, shudder and vibration. Tighten the lug nuts in sequence to 113-153 Nm (83-112 ft. lbs.). GENERAL SPECIFICATIONS Wheel Stud and Lug Nut: M12 x 1.75 - 19mm hex Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Wheel Fastener: Service and Repair Front Removal WARNING: The electrical power to the air suspension system must be turned off prior to hoisting, jacking or towing an air suspension vehicle. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. If equipped, turn the air suspension service switch off. 2. Raise the vehicle on a hoist. 3. Remove the wheel and tire assembly. 4. Remove the front disc brake hub and brake disc. 5. Using a suitable press, remove the wheel stud from the front disc brake hub and brake disc. Installation 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 2428 Wheel Fastener: Service and Repair Rear Special Tool(s) Removal CAUTION: Never use a hammer to remove the lug bolt. Damage to the axle flange, hub flange, wheel bearing or hub bearing can result. 1. WARNING: The electrical power to the air suspension system must be turned off prior to hoisting, jacking or towing an air suspension vehicle. Failure to do so can result in unexpected inflation or deflation of the air springs and/or shocks which can result in shifting of the vehicle during these operations. Turn the air suspension service switch off, if so equipped. 2. Raise the vehicle and install safety stands. 3. Remove the wheel and tire assembly. 4. Remove the rear disc brake caliper, rear disc support bracket and brake disc if so equipped. Support rear disc brake caliper with safety wire. If drum brake, proceed to Step 5. 5. Remove the rear brake drum. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 2429 6. Using C-Frame and Clamp Assembly Tool, press the lug bolt from its seat and discard. Installation CAUTION: Never use air tools to install lug bolts. The serrations can be stripped from the stud. 1. Insert a new wheel stud in the hole in the axle flange or hub flange, making sure serrations are aligned with those made by the original lug bolt. 2. Seat new wheel stud in axle flange or hub flange. ^ Place four flatwashers over the outside end of the wheel stud. ^ Thread a standard lug nut with the flat side against the washers. ^ Tighten the lug nut until the wheel stud head seats against the back side of the flange. 3. Remove the lug nut and flatwashers. 4. Install the brake disc, rear disc support bracket and the rear disc brake caliper, if so equipped. If drum brake, proceed to Step 5. 5. Install the rear brake drum. 6. Install the wheel and tire assembly. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 2430 7. Lower the vehicle. 8. Turn the air suspension service switch on, if so equipped. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Page 2431 Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation Vehicle Lifting and Jacking JACKING WARNING - THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT DOWN PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. - DO NOT RUN THE ENGINE WHEN JACKING THE VEHICLE. THE WHEELS CONTACTING THE GROUND COULD CAUSE THE VEHICLE TO MOVE. - SUPPORT THE VEHICLE PRIOR TO PERFORMING ANY PROCEDURE REQUIRING THE VEHICLE TO BE JACKED OFF THE GROUND. - MAKE SURE THE JACK AND JACK STANDS ARE PROPERLY LOCATED TO PREVENT THE VEHICLE FROM FALLING. - WHEEL CHOCKS SHOULD BE USED TO PREVENT THE VEHICLE FROM ROLLING AND FALLING OFF THE JACK. CAUTION: Never use a halfshaft as a lifting point. Jacking Points - Front, 4x4 The jacking point is a raised boss located on the front suspension lower arm. Jacking Points - Front, 4x2 The jacking point is a flat portion on the frame indicated by the arrow cut out. The jacking point is located behind the front tire and wheel assembly. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation > Page 2435 Jacking Points - Rear CAUTION: Never use the differential housing as a lifting point. The rear jacking points are located on the rear axle. LIFTING WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRING WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE PROCEDURES. CAUTION: Damage to suspension, exhaust and steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle Lifting Points - Twin Post Hoist Locate the front hoist adapters and rear hoist adapters (top of frame arc) as indicated. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation > Page 2436 Vehicle Lifting: Service and Repair Vehicle Lifting and Jacking JACKING WARNING - THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT DOWN PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. - DO NOT RUN THE ENGINE WHEN JACKING THE VEHICLE. THE WHEELS CONTACTING THE GROUND COULD CAUSE THE VEHICLE TO MOVE. - SUPPORT THE VEHICLE PRIOR TO PERFORMING ANY PROCEDURE REQUIRING THE VEHICLE TO BE JACKED OFF THE GROUND. - MAKE SURE THE JACK AND JACK STANDS ARE PROPERLY LOCATED TO PREVENT THE VEHICLE FROM FALLING. - WHEEL CHOCKS SHOULD BE USED TO PREVENT THE VEHICLE FROM ROLLING AND FALLING OFF THE JACK. CAUTION: Never use a halfshaft as a lifting point. Jacking Points - Front, 4x4 The jacking point is a raised boss located on the front suspension lower arm. Jacking Points - Front, 4x2 The jacking point is a flat portion on the frame indicated by the arrow cut out. The jacking point is located behind the front tire and wheel assembly. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation > Page 2437 Jacking Points - Rear CAUTION: Never use the differential housing as a lifting point. The rear jacking points are located on the rear axle. LIFTING WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRING WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE PROCEDURES. CAUTION: Damage to suspension, exhaust and steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle Lifting Points - Twin Post Hoist Locate the front hoist adapters and rear hoist adapters (top of frame arc) as indicated. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications Compression Pressure Limit Chart Compression Pressure Limit Chart The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 2443 Compression Check: Testing and Inspection 1. Make sure the oil in the crankcase is of the correct viscosity and at the proper level and that the battery is properly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all the spark plugs. 2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the Compression Tester in the No. 1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, and using the auxiliary starter switch, crank the engine a minimum of five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Compression Pressure Limit Chart Compression Pressure Limit Chart The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. If one or more cylinders reads low, squirt approximately one tablespoon of Super Premium SAE 5W30 Motor Oil, X0-5W30-QSP meeting Ford specification WSS-M2C153-G on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. - If compression improves considerably, piston rings are faulty. - If compression does not improve, valves are sticking or seating improperly. - If two adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications Camshaft Bearing: Specifications Camshaft Bearing Cap Bolts - Windsor Engines 8-12 Nm (71.4-107.1 in.lb) Camshaft Bearing Cap Bolts - Romeo Engines 8-12 Nm (71.4-107.1 in.lb) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft Sprocket Bolt M10 bolt: Tighten in two stages. Stage 1: Tighten to 40 Nm (30 ft.lbs.) Stage 2: Tighten an additional 90° M12 bolt: Tighten to 120 Nm (90 ft.lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications Camshaft: Specifications Lobe Lift Exhaust 7.49744 mm Intake 7.11038 mm Allowable Lift Loss 0 mm Valve Lift @ Zero Lash Intake 13.01 mm Exhaust 13.75 mm Camshaft End Play 0.027-0.190 mm End Play Service Limit 0.025-0.190 mm Journal to Bearing Clearance 0.076-0.025 mm Journal Diameters 26.962-26.936 mm Journal Inside Diameter (Cap Assembled) 27.012-26987 mm Camshaft Runout 0.03 mm Full indicator measurement on all journals when supported on front and rear journals. (4 Places) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 2454 Camshaft: Service and Repair Removal 1. Remove the timing chains. CAUTION: At no time, when the timing chains are removed and the cylinder heads are installed may the crankshaft or camshaft be rotated. Severe piston and valve damage will occur. 2. Remove the camshaft roller followers. 3. On engines with bolt on sprockets, remove the camshaft sprocket 1 Remove the bolt. 2 Remove the camshaft sprocket. 4. NOTE: The Windsor engine is shown; the Romeo engine is similar. Remove the thirteen camshaft bearing cap bolts. 5. NOTE: The Windsor cylinder head is shown; the Romeo cylinder head is similar. Remove the camshaft bearing caps. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 2455 6. Remove the camshaft from the cylinder head. Installation All Vehicles 1. Lubricate the camshaft journals. - Use Super Premium 5W30 Motor Oil X0-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. 2. Install the camshaft onto the cylinder head. 3. Lubricate the camshaft bearing caps. - Use Super Premium 5W30 Motor Oil X0-5W30-QSP or equivalent meeting Ford specifications WSS-M2C153-0. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 2456 4. On Windsor engines, install the camshaft bearing caps. - Position the camshaft bearing caps. - Loosely install the bolts. Romeo Engine 5. On Romeo engines, install the camshaft bearing caps. 1 Position the camshaft bearing caps. 2 Loosely install the bolts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 2457 Windsor Engine 6. On Windsor engines, tighten the bolts in the sequence shown. Romeo Engine 7. On Romeo engines, tighten the bolts in the sequence shown. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 2458 8. On Romeo engines, install the camshaft sprocket spacer. 1 Position the camshaft sprocket spacer. 2 Install the bolt. All Vehicles 9. Install the roller followers. 10. Install the timing chains. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 2459 Camshaft: Tools and Equipment Special Tool Special Tool Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair Lifter / Lash Adjuster: Service and Repair HYDRAULIC LASH ADJUSTERS Removal 1. Remove the camshaft roller followers. 2. Remove the valve tappets. Installation 1. Install the valve tappets. 2. Install the camshaft roller followers. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold Rocker Arm Assembly: Customer Interest Engine - Rough Idle/Noise When Cold Article No. 00-26-1 12/25/00 ^ ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 ^ NOISE - FROM ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 FORD: 1997-1999 F-250 LD 1997-2000 ECONOLINE, EXCURSION, EXPEDITION, F-150 1999-2000 F SUPER DUTY LINCOLN: 1998-1999 NAVIGATOR ISSUE Some vehicles equipped with a 4.6L, 5.4L, or 6.8L engine may exhibit a rough idle/miss after start-up in cold ambient temperatures (less than -12°C/10 ° F). This may be caused by a roller finger follower(s) being dislodged from the valve. This may result in damage to the camshaft, roller finger follower, valve, retainer, etc. A procedure is now available to service this condition. ACTION Inspect and replace any worn or damaged engine valve components and install new retaining clip and lash adjuster for service. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform normal engine diagnostic routines before opening valve covers. If the valve train is suspect, remove the valve covers and look for Roller Finger Follower(s) (RFF) that may have become dislodged. 1. Inspect the following parts that may have been damaged by any dislodged roller finger followers: ^ Cam lobes (chipped or grooved) ^ Valve stem tips (mushroomed, metal displaced, or bent) ^ Roller finger followers (chipped or grooved) ^ Inspect valve guide only if its corresponding RFF or valve stem tip is damaged. Replace damaged parts as necessary. 2. If follower(s) are damaged, replaced as necessary, otherwise re-use followers in same location as removed from head. 3. Remove all intake and exhaust lash adjusters from the engine and replace with service-only Lash Adjusters (YL3Z-6500-AA). Refer to the appropriate workshop Manual, Section 303-01B for service procedures and tooling necessary to compress the valve springs and remove the roller followers. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2471 NOTE REFER TO FIGURE 1 FOR INSTALLATION OF THE NEW RETAINING CLIPS (YL3Z-6A539-AA), TO THE ROLLER FINGER FOLLOWER. 4. Using a valve spring compression tool, install followers and the attached retaining clips by pushing clips onto lash adjuster. NOTE THE CLIP IS NOT REMOVABLE FROM ADJUSTER ONCE IT HAS BEEN SNAPPED INTO PLACE. IF THE ENGINE NEEDS TO BE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2472 SERVICED AT A LATER DATE, REMOVE THE RFF BY BENDING UP THE CLIP. LEAVE LASH ADJUSTER IN THE ENGINE WITH THE CLIP WHILE REMOVING THE FOLLOWER. THEN REMOVE THE LASH ADJUSTER FROM THE HEAD AND SNIP/CUT THE CLIP FROM THE LASH ADJUSTER. REPLACE WITH A NEW CLIP ON FOLLOWER DURING INSTALLATION. 5. Check valve train for proper assembly and reinstall valve covers as outlined in the Workshop Manual, Section 303-01B. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 497000, 499000, 602300, 608000, 608400, 609000, 609400, 613000, 613500, 702000, 702100 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold Rocker Arm Assembly: All Technical Service Bulletins Engine - Rough Idle/Noise When Cold Article No. 00-26-1 12/25/00 ^ ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 ^ NOISE - FROM ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 FORD: 1997-1999 F-250 LD 1997-2000 ECONOLINE, EXCURSION, EXPEDITION, F-150 1999-2000 F SUPER DUTY LINCOLN: 1998-1999 NAVIGATOR ISSUE Some vehicles equipped with a 4.6L, 5.4L, or 6.8L engine may exhibit a rough idle/miss after start-up in cold ambient temperatures (less than -12°C/10 ° F). This may be caused by a roller finger follower(s) being dislodged from the valve. This may result in damage to the camshaft, roller finger follower, valve, retainer, etc. A procedure is now available to service this condition. ACTION Inspect and replace any worn or damaged engine valve components and install new retaining clip and lash adjuster for service. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform normal engine diagnostic routines before opening valve covers. If the valve train is suspect, remove the valve covers and look for Roller Finger Follower(s) (RFF) that may have become dislodged. 1. Inspect the following parts that may have been damaged by any dislodged roller finger followers: ^ Cam lobes (chipped or grooved) ^ Valve stem tips (mushroomed, metal displaced, or bent) ^ Roller finger followers (chipped or grooved) ^ Inspect valve guide only if its corresponding RFF or valve stem tip is damaged. Replace damaged parts as necessary. 2. If follower(s) are damaged, replaced as necessary, otherwise re-use followers in same location as removed from head. 3. Remove all intake and exhaust lash adjusters from the engine and replace with service-only Lash Adjusters (YL3Z-6500-AA). Refer to the appropriate workshop Manual, Section 303-01B for service procedures and tooling necessary to compress the valve springs and remove the roller followers. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2478 NOTE REFER TO FIGURE 1 FOR INSTALLATION OF THE NEW RETAINING CLIPS (YL3Z-6A539-AA), TO THE ROLLER FINGER FOLLOWER. 4. Using a valve spring compression tool, install followers and the attached retaining clips by pushing clips onto lash adjuster. NOTE THE CLIP IS NOT REMOVABLE FROM ADJUSTER ONCE IT HAS BEEN SNAPPED INTO PLACE. IF THE ENGINE NEEDS TO BE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2479 SERVICED AT A LATER DATE, REMOVE THE RFF BY BENDING UP THE CLIP. LEAVE LASH ADJUSTER IN THE ENGINE WITH THE CLIP WHILE REMOVING THE FOLLOWER. THEN REMOVE THE LASH ADJUSTER FROM THE HEAD AND SNIP/CUT THE CLIP FROM THE LASH ADJUSTER. REPLACE WITH A NEW CLIP ON FOLLOWER DURING INSTALLATION. 5. Check valve train for proper assembly and reinstall valve covers as outlined in the Workshop Manual, Section 303-01B. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 497000, 499000, 602300, 608000, 608400, 609000, 609400, 613000, 613500, 702000, 702100 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Rod Bearing to Journal Clearance 0.064-0.026 mm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Bolt Connecting Rod: Specifications Connecting Rod Bearing Cap Bolts Stage 1 40-45 Nm (30-33 ft.lb) Stage 2 Rotate 90°-120° Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Bolt > Page 2488 Connecting Rod: Specifications Connecting Rod Bolts Stage 1 40-45 Nm Stage 2 Rotate 90-120 Degrees Pin Bore Diameter 22.012-22.024 mm Pin Bore Clearance 0.009-0.0235 mm Big End Journal Inside Diameter with Assembled Liners 53.049-53.027 mm Rod Bearing to Journal Clearance 0.064-0.026 mm Rod Length (Centerline Bore-to-Bore) 169.1 mm Alignment Bore-to-Bore Max. Twist + \ - 0.05 mm Bore-to-Bore Max. Bend + \ - 0.038 mm Side Play (As Assembled to Crank) Standard Play 0.300 + \ - 0.175 mm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Connecting Rod Bolt > Page 2489 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 2490 Special Tool Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Gear/Sprocket > Component Information > Specifications Crankshaft Gear/Sprocket: Specifications Crankshaft Pulley Bolt Stage 1 90 Nm (66.60 ft.lb) Stage 2 Loosen the bolt Stage 3 47-53 Nm (34-39 ft.lb) Stage 4 Additional 85-90 degrees Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > General Specifications Crankshaft Main Bearing: Specifications General Specifications Crankshaft Journal to Main Bearing Clearance ............................................................................................................................................ 0.048-0.024mm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications > General Specifications > Page 2498 Crankshaft Main Bearing: Specifications Torque Specifications and Procedures Torque Specifications - Crankshaft Main Bearing Bolts Vertical Tighten the bolts in two steps in the sequence shown. Step 1: Tighten to 40 Nm (30 ft. lbs.). - Step 2: Tighten an additional 90 degrees. Side Bolts Install the side bolts and tighten in two steps, in the sequence shown. Step 1: Tighten to 27-33 Nm (20-24 ft. lbs.). - Step 2: Tighten an additional 85-95 degrees. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications Crankshaft Main Bearing Bolts Vertical Stage 1 37-43 Nm Stage 2 Additional 85-95 Degrees Horizontal Stage 1 27-33 Nm Stage 2 Additional 85-95 Degrees Main Bearing Journal Diameter 67.483-67.503 mm Maximum Out-of-Round 0.0075 mm Maximum Taper (Straightness) 0.004 mm Runout (3 Places) 0.05 mm Clearance 0.048-0.024 mm Connecting Rod Journal Diameter 53.003-52.983 mm Maximum Out-of-Round 0.0075 mm Maximum Taper 0.004 mm Crankshaft End Play 0.075-0.377 mm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 2502 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 2503 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications > Page 2504 Crankshaft: Tools and Equipment Special Tools Special Tool Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair Engine Block Heater: Service and Repair Removal 1. Drain the cooling system. 2. Disconnect the (A) block heater wire extension from the (B) block heater wiring and remove. 3. Raise and support the vehicle. 4. Disconnect the (A) block heater wiring from the (B) block heater and remove. 5. Remove the block heater. 1 CAUTION: Do not loosen the block heater retaining screw more than necessary for removal. Loosen the block heater retaining screw. 2 Twist and slide the block heater to release the retainer clip and remove. Discard the retainer clip. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Page 2508 1. NOTE: To ease installation, coat the block heater seal and the cylinder block hole with Premium Long Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Expansion/Freeze Plug > Component Information > Tools and Equipment Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Harmonic Balancer Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft Damper Pulley Bolt Stage 1 90 Nm Stage 2 Loosen 360 Degrees Stage 3 47-53 Nm Stage 4 Rotate 85-90 Degrees Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Harmonic Balancer > Page 2516 Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft Pulley Bolt Stage 1 90 Nm (66.60 ft.lb) Stage 2 Loosen the bolt Stage 3 47-53 Nm (34-39 ft.lb) Stage 4 Additional 85-90 degrees Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2517 Harmonic Balancer - Crankshaft Pulley: Service and Repair Removal 1. Remove the engine cooling fan and fan shroud. 2. Remove the drive belt. 3. Remove the crankshaft pulley bolt. 4. Use the Crankshaft Damper Remover to remove the crankshaft pulley. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2518 1. NOTE: If not secured within four minutes, sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M513392-A. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply silicone to the woodruff key slot on the crankshaft pulley. Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6. 2. Use the Crankshaft Damper Replacer to install the crankshaft pulley. 3. Install the bolt and washer. Tighten the bolt in four stages. - Stage 1: Tighten to 90 Nm (66.15 ft. lbs.). - Stage 2: Loosen the bolt. - Stage 3: Tighten to 47-53 Nm (34-39 ft. lbs.). - Stage 4: Tighten an additional 85-90°. 4. Install the drive belt. 5. Install the engine cooling fan and the fan shroud. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2519 Special Tool Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Piston Diameter (Grade 2) at Right Angle to Pin Bore 90.180 + \ - 0.005 mm Piston to Bore Clearance (-0.005) to +0.025 mm Pin Bore Diameter 22.0005-22.014 mm Ring Groove Width Top 0.13-0.28 mm Intermediate 0.25-0.40 mm Oil Control 0.15-0.65 mm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 2523 Piston: Tools and Equipment Special Tools Special Tool Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications Piston Pin: Specifications Pin Diameter 22.0005-22.0030 mm Clearance (Neg. or Pos.) 0.01395-0.005 mm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer does not indicate whether this vehicle has adjustable or non-adjustable valves. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Gauge Special Tool(s) WARNING - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the Schrader valve cap and install the Fuel Pressure Gauge. 2. Open the manual valve slowly on the Fuel Pressure Gauge and relieve the fuel pressure. - This will drain some fuel out of the system. Place the fuel in a suitable container. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold Rocker Arm Assembly: Customer Interest Engine - Rough Idle/Noise When Cold Article No. 00-26-1 12/25/00 ^ ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 ^ NOISE - FROM ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 FORD: 1997-1999 F-250 LD 1997-2000 ECONOLINE, EXCURSION, EXPEDITION, F-150 1999-2000 F SUPER DUTY LINCOLN: 1998-1999 NAVIGATOR ISSUE Some vehicles equipped with a 4.6L, 5.4L, or 6.8L engine may exhibit a rough idle/miss after start-up in cold ambient temperatures (less than -12°C/10 ° F). This may be caused by a roller finger follower(s) being dislodged from the valve. This may result in damage to the camshaft, roller finger follower, valve, retainer, etc. A procedure is now available to service this condition. ACTION Inspect and replace any worn or damaged engine valve components and install new retaining clip and lash adjuster for service. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform normal engine diagnostic routines before opening valve covers. If the valve train is suspect, remove the valve covers and look for Roller Finger Follower(s) (RFF) that may have become dislodged. 1. Inspect the following parts that may have been damaged by any dislodged roller finger followers: ^ Cam lobes (chipped or grooved) ^ Valve stem tips (mushroomed, metal displaced, or bent) ^ Roller finger followers (chipped or grooved) ^ Inspect valve guide only if its corresponding RFF or valve stem tip is damaged. Replace damaged parts as necessary. 2. If follower(s) are damaged, replaced as necessary, otherwise re-use followers in same location as removed from head. 3. Remove all intake and exhaust lash adjusters from the engine and replace with service-only Lash Adjusters (YL3Z-6500-AA). Refer to the appropriate workshop Manual, Section 303-01B for service procedures and tooling necessary to compress the valve springs and remove the roller followers. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2542 NOTE REFER TO FIGURE 1 FOR INSTALLATION OF THE NEW RETAINING CLIPS (YL3Z-6A539-AA), TO THE ROLLER FINGER FOLLOWER. 4. Using a valve spring compression tool, install followers and the attached retaining clips by pushing clips onto lash adjuster. NOTE THE CLIP IS NOT REMOVABLE FROM ADJUSTER ONCE IT HAS BEEN SNAPPED INTO PLACE. IF THE ENGINE NEEDS TO BE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2543 SERVICED AT A LATER DATE, REMOVE THE RFF BY BENDING UP THE CLIP. LEAVE LASH ADJUSTER IN THE ENGINE WITH THE CLIP WHILE REMOVING THE FOLLOWER. THEN REMOVE THE LASH ADJUSTER FROM THE HEAD AND SNIP/CUT THE CLIP FROM THE LASH ADJUSTER. REPLACE WITH A NEW CLIP ON FOLLOWER DURING INSTALLATION. 5. Check valve train for proper assembly and reinstall valve covers as outlined in the Workshop Manual, Section 303-01B. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 497000, 499000, 602300, 608000, 608400, 609000, 609400, 613000, 613500, 702000, 702100 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold Rocker Arm Assembly: All Technical Service Bulletins Engine - Rough Idle/Noise When Cold Article No. 00-26-1 12/25/00 ^ ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 ^ NOISE - FROM ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 FORD: 1997-1999 F-250 LD 1997-2000 ECONOLINE, EXCURSION, EXPEDITION, F-150 1999-2000 F SUPER DUTY LINCOLN: 1998-1999 NAVIGATOR ISSUE Some vehicles equipped with a 4.6L, 5.4L, or 6.8L engine may exhibit a rough idle/miss after start-up in cold ambient temperatures (less than -12°C/10 ° F). This may be caused by a roller finger follower(s) being dislodged from the valve. This may result in damage to the camshaft, roller finger follower, valve, retainer, etc. A procedure is now available to service this condition. ACTION Inspect and replace any worn or damaged engine valve components and install new retaining clip and lash adjuster for service. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform normal engine diagnostic routines before opening valve covers. If the valve train is suspect, remove the valve covers and look for Roller Finger Follower(s) (RFF) that may have become dislodged. 1. Inspect the following parts that may have been damaged by any dislodged roller finger followers: ^ Cam lobes (chipped or grooved) ^ Valve stem tips (mushroomed, metal displaced, or bent) ^ Roller finger followers (chipped or grooved) ^ Inspect valve guide only if its corresponding RFF or valve stem tip is damaged. Replace damaged parts as necessary. 2. If follower(s) are damaged, replaced as necessary, otherwise re-use followers in same location as removed from head. 3. Remove all intake and exhaust lash adjusters from the engine and replace with service-only Lash Adjusters (YL3Z-6500-AA). Refer to the appropriate workshop Manual, Section 303-01B for service procedures and tooling necessary to compress the valve springs and remove the roller followers. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2549 NOTE REFER TO FIGURE 1 FOR INSTALLATION OF THE NEW RETAINING CLIPS (YL3Z-6A539-AA), TO THE ROLLER FINGER FOLLOWER. 4. Using a valve spring compression tool, install followers and the attached retaining clips by pushing clips onto lash adjuster. NOTE THE CLIP IS NOT REMOVABLE FROM ADJUSTER ONCE IT HAS BEEN SNAPPED INTO PLACE. IF THE ENGINE NEEDS TO BE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rocker Arm Assembly: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2550 SERVICED AT A LATER DATE, REMOVE THE RFF BY BENDING UP THE CLIP. LEAVE LASH ADJUSTER IN THE ENGINE WITH THE CLIP WHILE REMOVING THE FOLLOWER. THEN REMOVE THE LASH ADJUSTER FROM THE HEAD AND SNIP/CUT THE CLIP FROM THE LASH ADJUSTER. REPLACE WITH A NEW CLIP ON FOLLOWER DURING INSTALLATION. 5. Check valve train for proper assembly and reinstall valve covers as outlined in the Workshop Manual, Section 303-01B. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 497000, 499000, 602300, 608000, 608400, 609000, 609400, 613000, 613500, 702000, 702100 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Specifications Valve Cover: Specifications Valve Cover Bolts 8-12 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side Valve Cover: Service and Repair Right Side Removal 1. Disconnect the battery ground cable. 2. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the accelerator control splash shield. 3. Remove the Engine Air Cleaner (ACL). 4. Disconnect the crankcase ventilation hose from the valve cover. 5. Disconnect the two fuse block cable ends from the starter relay. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2556 6. Disconnect the two 42-pin bulkhead electrical connections and remove them from the junction block bracket. 7. Disconnect the 16-pin electrical connection and the single pin electrical connection. 8. Remove the bolts and the junction block bracket. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2557 9. Disconnect the heater water hose. 10. Disconnect the heater water hose. 11. Disconnect the heater water hose from the heater core and remove the heater water hose. 12. Disconnect the RH fuel injector electrical connections. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2558 13. On 5.4L engines, disconnect the RH ignition coil electrical connections. 14. Disconnect the climate vacuum connection. 15. Raise and support the vehicle. 16. Disconnect the A/C compressor electrical connection. 17. Disconnect the Crankshaft Position (CKP) sensor electrical connection. 18. Position the wiring harness aside. 19. Lower the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2559 20. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. NOTE: The bolts are part of the valve cover and cannot be removed. Loosen the bolts and remove the valve cover. Remove the valve cover gasket. Clean and inspect the mating surface. Installation All Vehicles 1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. NOTE: If the valve cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M513392-A. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply the silicone in two places where the engine front cover meets the cylinder head. Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2560 2. Position the valve cover on the cylinder head and loosely install the valve cover bolts. Romeo Engine Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2561 Windsor Engine 3. Tighten the bolts in the sequence shown. All Vehicles 4. Connect the heater water hose to the heater core. 5. Connect the heater water hose and position the clamp. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2562 6. Connect the (B) heater water hose and position the (A) clamp. 7. Install the junction block bracket and the bolts. 8. Connect the 16-pin electrical connection and the single pin electrical connection. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2563 9. Connect the two 42-pin bulkhead electrical connections. 10. Connect the two fuse cable leads to the starter relay. 11. Raise and support the vehicle. 12. Connect the crankshaft position sensor electrical connection. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2564 13. Connect the A/C compressor electrical connection. 14. Lower the vehicle. 15. Install the Positive Crankcase Ventilation Valve (PCV valve) and crankcase ventilation hose into the valve cover. 16. Install the engine air cleaner. 17. Install the accelerator control splash shield. 18. Connect the battery ground cable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2565 Valve Cover: Service and Repair Left Side Removal All Vehicles 1. Disconnect the battery ground cable. 2. Remove the engine air cleaner and the air cleaner outlet tube. 3. Disconnect the power steering fluid reservoir and bracket. 1 Remove the bolts. 2 Position the power steering fluid reservoir and bracket aside. 4. Remove the crankcase ventilation tube from the valve cover. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2566 4.6 L Engine 5.4 L Engine 5. Remove the EGR valve-to-exhaust manifold tube. - Disconnect the upper and lower EGR valve-to-exhaust manifold tube fittings. - Disconnect the two DPFE hoses. All Vehicles Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2567 6. Disconnect the LH fuel injector electrical connections. 7. On 5.4L engines, disconnect the LH ignition coil electrical connections. 8. Disconnect the Camshaft Position (CMP) sensor. 9. Lift the engine sensor control wiring harness off of the valve cover studs. 10. NOTE: The intake manifold is removed for clarity. NOTE: The bolts are part of the valve cover and should not be removed. Remove the LH valve cover. Fully loosen the bolts and remove the valve cover. - Inspect the valve cover gasket and clean the mating surface of the cylinder head. Installation All Vehicles Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2568 1. NOTE: If not secured within four minutes, the sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-A or equivalent meeting Ford specification WSE-M5B392-RA. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply a bead of silicone in two places where the engine front cover meets the cylinder head. Use Silicone Gasket and Sealer F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6. 2. Position the (A) valve cover and the valve cover gasket on the (B) cylinder head, and loosely install the bolts. Romeo Engine Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2569 Windsor Engine 3. Tighten the bolts in the sequence shown. All Vehicles 4. Position the engine sensor control wiring harness onto the valve cover studs. 5. Connect the CMP electrical connector. 6. On 5.4L engines, connect the LH ignition coil electrical connectors, Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2570 7. Connect the LH fuel injector electrical connectors. 4.6 L Engine Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Right Side > Page 2571 5.4 L Engine 8. Connect the EGR valve to exhaust manifold tube upper fitting. - On 4.6L engines, tighten both fittings starting at the top in two stages. Stage 1: Hand tighten. - Stage 2: Tighten to 35-45 Nm (26-33 ft. lbs.). - On 5.4L engines, tighten both fittings starting at the top in two Stages. Stage 1: Hand-tighten. - Stage 2: Tighten to 55-65 Nm (41-47 ft. lbs.). All Vehicles 9. Connect the crankcase ventilation tube to the valve cover. 10. Install the Engine Air Cleaner (ACL) and air cleaner outlet tube. 11. Install the power steering fluid reservoir and bracket. 1 Position the power steering fluid reservoir and bracket. 2 Install the bolts. 12. Connect the battery ground cable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Testing and Inspection Valve Guide: Testing and Inspection INNER DIAMETER 1. Measure the inner diameter of the valve guides in two directions where indicated. 2. If the valve guide is not within specifications, ream the valve guide and install a valve with an oversize stem or remove the valve guide and install a new valve guide. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Testing and Inspection > Page 2575 Valve Guide: Service and Repair GUIDE REAMING 1. Use a hand-reaming kit to ream the valve guide. 2. Reface the valve seat. 3. Clean the sharp edges left by reaming. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications Valve Seat: Specifications Valve Seat Width Intake 1.3-1.5 mm Exhaust 2.1-1.9 mm Valve Seat Angle 45.00-44.50 deg Valve Seat Runout 0.025 mm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications Valve Spring: Specifications Valve Spring Compression Pressure Intake 720-800 N at 28.02 mm Exhaust 720-800 N at 28.02 mm Valve Spring Free Length Intake 53.37 mm Exhaust 53.37 mm Valve Spring Installed Pressure Intake 287.19-321.19 N at 42.56 mm Exhaust 287.19-321.19 N at 42.56 mm Valve Springs Installed Pressure Service Limit Intake 5% Pressure Loss N at 28.80 mm Exhaust 5% Pressure Loss N at 28.80 mm Valve Springs Out of Square Limit Intake 2.0 deg Exhaust 2.0 deg Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Testing and Inspection > Free Length Valve Spring: Testing and Inspection Free Length 1. Measure the free length of each valve spring. - If out of specification, replace as necessary. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Testing and Inspection > Free Length > Page 2584 Valve Spring: Testing and Inspection Installed Length 1. Measure the installed length of each valve spring. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Testing and Inspection > Free Length > Page 2585 Valve Spring: Testing and Inspection Squareness 1. Measure the out-of-square on each valve spring. - Turn the valve spring and observe the space between the top of the valve spring and the square. Replace the valve spring if out of square. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Testing and Inspection > Free Length > Page 2586 Valve Spring: Testing and Inspection Strength 1. Use a Valve/Clutch Spring Tester to check the valve spring for proper strength at the specified valve spring length. - If out of specification, replace as necessary Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Testing and Inspection > Page 2587 Valve Spring: Service and Repair Special Tools Removal 1. Remove the camshaft roller followers. 2. Position the piston at the top of the stroke. 3. Remove the spark plug and install compressed air in the cylinder to hold both valves in position. CAUTION: If air pressure has forced the piston to the bottom of the cylinder, any loss of air pressure will allow the valve to fall into the cylinder. If air pressure must be removed, support the valve prior to removal. 4. Use the Valve Spring Compressor to compress the valve springs. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Testing and Inspection > Page 2588 5. Remove the (A) valve spring retainer keys, the (B) valve spring retainers, and the (C) valve spring. Installation 1. Position the valve spring and the valve spring retainers. 2. Install the Valve Spring Spacer between the valve spring coils to prevent valve stem seal damage. 3. Use the Valve Spring Compressor to compress the valve spring. Install the valve spring retainer keys. 4. Install the camshaft roller followers. 5. Install the spark plug. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Valve: > 00-26-1 > Dec > 00 > Engine Rough Idle/Noise When Cold Valve: Customer Interest Engine - Rough Idle/Noise When Cold Article No. 00-26-1 12/25/00 ^ ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 ^ NOISE - FROM ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 FORD: 1997-1999 F-250 LD 1997-2000 ECONOLINE, EXCURSION, EXPEDITION, F-150 1999-2000 F SUPER DUTY LINCOLN: 1998-1999 NAVIGATOR ISSUE Some vehicles equipped with a 4.6L, 5.4L, or 6.8L engine may exhibit a rough idle/miss after start-up in cold ambient temperatures (less than -12°C/10 ° F). This may be caused by a roller finger follower(s) being dislodged from the valve. This may result in damage to the camshaft, roller finger follower, valve, retainer, etc. A procedure is now available to service this condition. ACTION Inspect and replace any worn or damaged engine valve components and install new retaining clip and lash adjuster for service. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform normal engine diagnostic routines before opening valve covers. If the valve train is suspect, remove the valve covers and look for Roller Finger Follower(s) (RFF) that may have become dislodged. 1. Inspect the following parts that may have been damaged by any dislodged roller finger followers: ^ Cam lobes (chipped or grooved) ^ Valve stem tips (mushroomed, metal displaced, or bent) ^ Roller finger followers (chipped or grooved) ^ Inspect valve guide only if its corresponding RFF or valve stem tip is damaged. Replace damaged parts as necessary. 2. If follower(s) are damaged, replaced as necessary, otherwise re-use followers in same location as removed from head. 3. Remove all intake and exhaust lash adjusters from the engine and replace with service-only Lash Adjusters (YL3Z-6500-AA). Refer to the appropriate workshop Manual, Section 303-01B for service procedures and tooling necessary to compress the valve springs and remove the roller followers. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Valve: > 00-26-1 > Dec > 00 > Engine Rough Idle/Noise When Cold > Page 2597 NOTE REFER TO FIGURE 1 FOR INSTALLATION OF THE NEW RETAINING CLIPS (YL3Z-6A539-AA), TO THE ROLLER FINGER FOLLOWER. 4. Using a valve spring compression tool, install followers and the attached retaining clips by pushing clips onto lash adjuster. NOTE THE CLIP IS NOT REMOVABLE FROM ADJUSTER ONCE IT HAS BEEN SNAPPED INTO PLACE. IF THE ENGINE NEEDS TO BE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Valve: > 00-26-1 > Dec > 00 > Engine Rough Idle/Noise When Cold > Page 2598 SERVICED AT A LATER DATE, REMOVE THE RFF BY BENDING UP THE CLIP. LEAVE LASH ADJUSTER IN THE ENGINE WITH THE CLIP WHILE REMOVING THE FOLLOWER. THEN REMOVE THE LASH ADJUSTER FROM THE HEAD AND SNIP/CUT THE CLIP FROM THE LASH ADJUSTER. REPLACE WITH A NEW CLIP ON FOLLOWER DURING INSTALLATION. 5. Check valve train for proper assembly and reinstall valve covers as outlined in the Workshop Manual, Section 303-01B. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 497000, 499000, 602300, 608000, 608400, 609000, 609400, 613000, 613500, 702000, 702100 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold Valve: All Technical Service Bulletins Engine - Rough Idle/Noise When Cold Article No. 00-26-1 12/25/00 ^ ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 ^ NOISE - FROM ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 FORD: 1997-1999 F-250 LD 1997-2000 ECONOLINE, EXCURSION, EXPEDITION, F-150 1999-2000 F SUPER DUTY LINCOLN: 1998-1999 NAVIGATOR ISSUE Some vehicles equipped with a 4.6L, 5.4L, or 6.8L engine may exhibit a rough idle/miss after start-up in cold ambient temperatures (less than -12°C/10 ° F). This may be caused by a roller finger follower(s) being dislodged from the valve. This may result in damage to the camshaft, roller finger follower, valve, retainer, etc. A procedure is now available to service this condition. ACTION Inspect and replace any worn or damaged engine valve components and install new retaining clip and lash adjuster for service. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform normal engine diagnostic routines before opening valve covers. If the valve train is suspect, remove the valve covers and look for Roller Finger Follower(s) (RFF) that may have become dislodged. 1. Inspect the following parts that may have been damaged by any dislodged roller finger followers: ^ Cam lobes (chipped or grooved) ^ Valve stem tips (mushroomed, metal displaced, or bent) ^ Roller finger followers (chipped or grooved) ^ Inspect valve guide only if its corresponding RFF or valve stem tip is damaged. Replace damaged parts as necessary. 2. If follower(s) are damaged, replaced as necessary, otherwise re-use followers in same location as removed from head. 3. Remove all intake and exhaust lash adjusters from the engine and replace with service-only Lash Adjusters (YL3Z-6500-AA). Refer to the appropriate workshop Manual, Section 303-01B for service procedures and tooling necessary to compress the valve springs and remove the roller followers. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2604 NOTE REFER TO FIGURE 1 FOR INSTALLATION OF THE NEW RETAINING CLIPS (YL3Z-6A539-AA), TO THE ROLLER FINGER FOLLOWER. 4. Using a valve spring compression tool, install followers and the attached retaining clips by pushing clips onto lash adjuster. NOTE THE CLIP IS NOT REMOVABLE FROM ADJUSTER ONCE IT HAS BEEN SNAPPED INTO PLACE. IF THE ENGINE NEEDS TO BE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 2605 SERVICED AT A LATER DATE, REMOVE THE RFF BY BENDING UP THE CLIP. LEAVE LASH ADJUSTER IN THE ENGINE WITH THE CLIP WHILE REMOVING THE FOLLOWER. THEN REMOVE THE LASH ADJUSTER FROM THE HEAD AND SNIP/CUT THE CLIP FROM THE LASH ADJUSTER. REPLACE WITH A NEW CLIP ON FOLLOWER DURING INSTALLATION. 5. Check valve train for proper assembly and reinstall valve covers as outlined in the Workshop Manual, Section 303-01B. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 497000, 499000, 602300, 608000, 608400, 609000, 609400, 613000, 613500, 702000, 702100 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > Page 2606 Valve: Specifications Valve Stem Guide Clearance Intake 0.069-0.020 mm Exhaust 36.0 mm Valve Head Diameter Intake 44.63-44.37 mm Exhaust 34.12-33.88 mm Valve Face Runout (Limit) 0.05 mm Valve Face Angle 45.75-45.25 deg Valve Stem Diameter Intake 6.995-6.975 mm Exhaust 6.970-6.949 mm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Testing and Inspection > Inspection Valve: Testing and Inspection Inspection 1. Inspect the following valve areas: 1 the end of the stem for grooves or scoring 2 the valve face and the edge for pits, grooves or scores 3 the valve head for signs of burning, erosion, warpage and cracking. 4 the valve head thickness for wear Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Testing and Inspection > Inspection > Page 2609 Valve: Testing and Inspection Seat Runout 1. Use the Valve Seat Runout Gauge to check valve seat runout. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Testing and Inspection > Inspection > Page 2610 Valve: Testing and Inspection Seat Width 1. Measure the valve seat width. If necessary, grind the valve seat to specification. - Measure the intake valve seat width. - Measure the exhaust valve seat width. - Recheck the valve spring installed length after the seats have been ground, and shim the valve springs as necessary to achieve the correct installed spring length. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Testing and Inspection > Inspection > Page 2611 Valve: Testing and Inspection Stem Diameter 1. Measure the diameter of each intake and exhaust valve stem at the points shown. Verify the diameter is within specification. - If out of specification, replace as necessary. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Testing and Inspection > Inspection > Page 2612 Valve: Testing and Inspection Inspection 1. Inspect the following valve areas: 1 the end of the stem for grooves or scoring 2 the valve face and the edge for pits, grooves or scores 3 the valve head for signs of burning, erosion, warpage and cracking. 4 the valve head thickness for wear Seat Runout 1. Use the Valve Seat Runout Gauge to check valve seat runout. Seat Width 1. Measure the valve seat width. If necessary, grind the valve seat to specification. - Measure the intake valve seat width. - Measure the exhaust valve seat width. - Recheck the valve spring installed length after the seats have been ground, and shim the valve springs as necessary to achieve the correct installed spring length. Stem Diameter Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Testing and Inspection > Inspection > Page 2613 1. Measure the diameter of each intake and exhaust valve stem at the points shown. Verify the diameter is within specification. - If out of specification, replace as necessary. Stem to Guide Clearance Special Tools NOTE: Valve stem diameter must be within specifications before checking valve stem to valve guide clearance. 1. NOTE: If necessary, use a magnetic base. Install a Valve Stem Clearance Tool on the valve stem and install a Dial Indicator with Bracketry. Lower the valve until the Valve Stem Clearance Tool contacts the upper surface of the valve guide. 2. Move the Valve Stem Clearance Tool toward the indicator and zero the indicator. Move the Valve Stem Clearance Tool away from the indicator and note the reading. The reading will be DOUBLE the valve stem-to-valve guide clearance. Valves with oversize stems will need to be installed if out of specification. Valve Refacing Measurements CAUTION: After grinding valves or valve seats, check valve clearance. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Testing and Inspection > Inspection > Page 2614 1. Check the valve head and seat. - Check valve angles. - Check margin width. - Be sure margin width is within specification. 2. Inspect for abnormalities on the valve face and seat. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications Drive Belt: Specifications Drive Belt Number Of Ribs 8 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Locations > With Air Conditioning Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Locations > With Air Conditioning > Page 2621 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Locations > Page 2622 Drive Belt: Description and Operation The accessory drive consists of the: drive belt. - generator pulley. - power steering pump pulley. - crankshaft vibration damper and pulley. - A/C clutch pulley (if equipped). - belt idler pulley. - drive belt tensioner. - water pump pulley. The accessory drive: has a single serpentine drive belt. The 4.2L engine drive belt has six ribs. - The 4.6L, and 5.4L engine drive belts have eight ribs. - has automatic tensioning. - is not adjustable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Drive Belt: Initial Inspection and Diagnostic Overview 1. Verify the concern by running the engine. V-Ribbed Belt With Cracks (Acceptable) V-Ribbed Belt With Chunks Of Rib Missing (Not Acceptable) 2. Inspect the drive belt for chunking, fraying and wear. Refer to the illustrations. 3. Check the drive belt for correct routing. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2625 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2626 Drive Belt: Component Tests and General Diagnostics Belt Tensioner NOTE: Tensioners are shown in free-state position against arm travel stops. 4.6L, 5.4L Drive Belt Tensioner/Belt Length Indicator With A/C Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2627 4.6L, 5.4L Belt, Drive Tensioner/Belt Length Indicator Without A/C Automatic tensioners are calibrated at the factory to provide the correct amount of tension to the belt. Unless a spring within the tensioner assembly breaks or some other mechanical part of the tensioner fails, there is no need to check tensioners for proper tension. The only mechanical check that need be made, if you have any doubt about the tensioner function, would be to remove the belt in the area of the tensioner, to avoid belt contact, then using the proper tool, rotate the tensioner from its relaxed position through its full stroke and back to the relaxed position to assure that there is no "stick, grab, bind," and to assure that there is tension on the spring. It is a normal condition for the tensioner to be moving, under certain conditions, when the engine is running. If the tensioner meets these criteria, it should be assumed to be a good tensioner. Drive Belt Misalignment CAUTION: Incorrect drive belt installation will cause excessive drive belt wear and may cause the drive belt to come off the drive pulleys. Non-standard replacement drive belts may track differently or improperly. If a replacement drive belt tracks improperly, replace it with an original equipment drive belt to avoid performance failure or loss of belt. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2628 With the engine running, check drive belt tracking. If the (A) edge of the drive belt rides beyond the edge of the pulleys, noise and premature wear may occur. Make sure the (B) drive belt rides correctly on the pulley. If a drive belt tracking condition exists, proceed with the following: Visually check the drive belt tensioner for damage, especially the mounting pad surface. If the drive belt tensioner is not installed correctly, the mounting surface pad will be out of position. This will result in chirp and squeal noises. With the engine running, visually observe the grooves in the pulleys (not the pulley flanges or pulley front surfaces) for excessive wobble. Replace components as required. - Check all accessories, mounting brackets and the drive belt tensioner for any interference that would prevent the component from mounting properly. Correct any interference condition and recheck belt tracking, - Tighten all accessories, mounting brackets, and drive belt tensioner retaining hardware to specification. Recheck the drive belt tracking. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > With A/C Drive Belt: Service and Repair With A/C Removal 1. Rotate the tensioner clockwise and remove the drive belt. Installation 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Service and Repair > With A/C > Page 2631 Drive Belt: Service and Repair Without A/C Removal 1. Rotate the tensioner counterclockwise and remove the drive belt. Installation 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications Drive Belt Tensioner: Specifications Drive Belt Tensioner Bolts 25 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications > Page 2635 Drive Belt Tensioner: Testing and Inspection For further information regarding this component, please refer to Drive Belt; Testing and Inspection. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Specifications > Page 2636 Drive Belt Tensioner: Service and Repair Removal 1. Remove the drive belt. 2. NOTE: The drive belt tensioner for a vehicle with air conditioning is shown, the drive belt tensioner for a vehicle without air conditioning is similar, except for the ribbed pulley. Remove the (A) bolts and the (B) drive belt tensioner. Installation 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2641 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2642 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2643 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2644 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2645 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2646 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2647 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2648 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2649 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2650 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2651 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2652 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2653 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2654 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2655 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2656 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2657 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2658 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2659 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2660 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2661 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2662 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2663 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2664 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2665 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2666 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2667 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2668 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2669 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2670 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2671 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2672 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2673 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2674 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2675 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2676 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2677 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2678 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2679 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2680 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2681 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2682 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2683 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2684 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2685 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2686 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2687 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2688 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2689 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2690 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2691 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2692 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2693 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2694 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2695 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2696 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2697 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2698 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2699 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2700 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2701 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2702 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2703 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2704 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2705 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2706 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2707 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2708 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2709 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2710 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2711 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2712 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2713 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2714 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2715 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2716 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2717 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2718 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2719 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2720 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2721 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2722 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2723 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2724 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2725 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2726 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2727 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2728 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2729 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2730 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2731 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2732 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2733 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2734 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 2735 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Technical Service Bulletins > Page 2736 Engine Mount: Specifications Motor Mount to Cylinder Block Bolts 53-72 Nm Motor Mount Through Bolts 68-92 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > LH Engine Mount: Service and Repair LH Special Tool Removal 1. Remove the fan shroud. 2. Remove the generator. 3. Install the 3-Bar Modular Engine Support Bracket on the engine using the generator mounting holes. 4. Raise the vehicle. 5. Remove the LH motor mount bolt. 6. Loosen the RH motor mount bolt. 7. Lower the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > LH > Page 2739 8. Install the 3-Bar Engine Support and raise the engine. 9. Raise the vehicle on the hoist. 10. Remove the bolts and remove the engine mount. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > LH > Page 2740 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > LH > Page 2741 Engine Mount: Service and Repair RH Special Tool Removal 1. Remove the fan shroud. 2. Remove the generator. 3. Install the 3-Bar Modular Engine Support Bracket on the engine using the generator mounting holes. 4. Raise the vehicle. 5. Remove the starter motor. 6. Remove the RH motor mount bolt. 7. Loosen the LH motor mount bolt. 8. Lower the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > LH > Page 2742 9. Install the 3-Bar engine Support and raise the engine. 10. Raise the vehicle on the hoist. 11. Remove the RH bolts and remove the engine mount. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > LH > Page 2743 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Page 2744 Special Tool Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Specifications Idler Pulley: Specifications Drive Belt Idler Pulley Bolt 25 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Specifications > Page 2748 Idler Pulley: Service and Repair Removal 1. Remove the drive belt. 2. Remove the (A) bolt and the (B) belt idler pulley. Installation 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure Oil Pressure Pressure @ 1500rpm 20-44 psi Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Specifications Engine Oil Dip Stick - Dip Stick Tube: Specifications Dipstick Tube Bolt ................................................................................................................................ ............................................ 8-12 Nm (71-106 lb in) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Specifications > Page 2756 Engine Oil Dip Stick - Dip Stick Tube: Service and Repair Removal 1. Remove LH exhaust manifold. 2. Remove the oil level indicator. 3. Remove the bolt. 4. Remove the oil level indicator tube. 5. NOTE: Lubricate the new O-ring with Ford Super Premium SAE 5W-30 Motor Oil X0-5W-30-QSP or equivalent meeting Ford specification WSS-M2C153-G. Replace the O-ring. Installation 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Drain Plug > Component Information > Specifications Engine Oil Drain Plug: Specifications Oil Pan Drain Plug 11-16 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications Technical Service Bulletin # 02-1-9 Date: 020121 Engine Oil - Oil Recommendations/Applications Article No. 02-1-9 01/21/02 ENGINE - ENGINE OIL - RECOMMENDED APPLICATIONS FOR SAE 5W-20 AND SAE 5W-30 MOTOR OILS - GASOLINE AND FLEXIBLE FUEL VEHICLES ONLY FORD: 1992-2002 CROWN VICTORIA 1993-1994 TEMPO 1993-1997 THUNDERBIRD 1993-2002 ESCORT, MUSTANG, TAURUS 1995-2000 CONTOUR 1998-2002 ESCORT ZX2 2000-2002 FOCUS 1993-1996 BRONCO 1993-1997 AEROSTAR 1993-2002 E SERIES, F-150, RANGER 1995-2002 WINDSTAR 1997-1999 F-250 LD 1997-2001 EXPLORER 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2000-2002 EXCURSION 2001-2002 ESCAPE LINCOLN: 1991-2002 TOWN CAR 1993-1998 MARK VIII 1993-2002 CONTINENTAL 2000-2002 LS 1998-2002 NAVIGATOR MERCURY: 1992-2002 GRAND MARQUIS 1993-1994 TOPAZ 1993-1997 COUGAR 1993-1999 TRACER 1993-2002 SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1997-2001 MOUNTAINEER This article is being republished in its entirety to update the vehicle models, engines and years affected. NOTE PLEASE REFER TO THE VEHICLE APPLICATION LIST LATER IN THIS TSB FOR A COMPLETE LIST OF VEHICLES AFFECTED BY THIS TSB. ISSUE Ford Motor Company now recommends SAE 5W-20 viscosity grade for servicing most gasoline and flexible fueled vehicles. ACTION All 2001 and 2002 vehicles where SAE 5W-20 is specified should be serviced at the recommended oil change intervals using SAE 5W-20. This oil is an improved formulation to improve fuel economy. Testing has validated this viscosity grade can be used in many previous model year vehicles. It is recommended ALL vehicles on the following Vehicle Application Listing be service with SAE 5W-20. All 2001-2002 vehicles other than those listed in the "Exception 2001 Vehicles" or "Exception 2002 Vehicles" chart are being filled with SAE 5W-20 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2764 motor oil at the factory and should also be serviced with SAE 5W-20 oil. Exception 2001 Vehicles Exception 2002 Vehicles NOTE IF VEHICLE IS NOT LISTED IN THIS APPLICATION, SAE 5W-30 OIL IS RECOMMENDED. REFER TO TSB 99-8-16. Parts Block OTHER APPLICABLE ARTICLES: 99-8-16 SUPERSEDES: 01-4-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 490000, 497000, 499000 Veh. App. Listing Approved For SAE 5W-20 Motor Oil ^ 1993-1996 1.9L Escort/Tracer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2765 ^ 1995-2000 2.0L Zetec Contour/Mystique ^ 1999-2002 2.0L Cougar ^ 1997-2002 2.0L Escort/Tracer ^ 1998-2002 2.0L Escort ZX2 ^ 2000-2002 2.0L Focus ^ 2001-2002 2.0L Escape ^ 1993-1997 2.3L Ranger ^ 1993-1994 2.3L Mustang ^ 1993-1994 2.3L Tempo/Topaz ^ 1998-2001 2.5L Ranger ^ 1995-2000 2.5L Contour/Mystique ^ 1999-2002 2.5L Cougar ^ 2001-2002 3.0L 4V Escape ^ 1996-2001 3.0L 4V Taurus/Sable ^ 1993-2002 3.0L (Vulcan) Aerostar/Ranger, ^ Taurus/Sable (Flexible Fuel and Gas) ^ 1995-2000 3.0L (Vulcan) Windstar ^ 1993-1994 3.0L (Vulcan) Tempo/Topaz ^ 2000-2002 3.0L 4V Lincoln LS ^ 1995-2002 3.8L Windstar ^ 1993-1997 3.8L Taurus/Sable, ^ Thunderbird/Cougar, Continental ^ 1994-2002 3.8L Mustang ^ 2002-2002 3.9L 4V Lincoln LS ^ 1997-2002 4.2L (SPI) F-150 (under 8500 GVW only), E-Series ^ 1996-2002 4.6L 2V Mustang ^ 1992-2002 4.6L Crown Victoria/Grand Marquis ^ 1991-2002 4.6L Town Car ^ 1994-1997 4.6L 2V Thunderbird/Cougar ^ 1996-2002 4.6L 4V Mustang Cobra ^ 1995-2002 4.6L 4V Continental ^ 1993-1998 4.6L 4V Mark VIII Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2766 ^ 1997-2002 4.6L 2V Triton F-150/250 (under 8500 GVW only), E-Series, Expedition ^ 1993-1999 4.9L E-Series, F-Series ^ 1993-1995 5.0L Mustang/Mustang Cobra ^ 1993-1993 5.0L Thunderbird/Cougar ^ 1997-2001 5.0L Explorer/Mountaineer ^ 1993-1996 5.0L E-Series, F-Series, Bronco ^ 2000-2002 5.4L Excursion ^ 1998-2002 5.4L 2V/4V Navigator ^ 1997-2002 5.4L 2V F-1501250 (under 8500 GVW only), Expedition, E-Series, E-350 Chassis/RV/Cutaway ^ 1993-1997 5.8L F-Series, Bronco ^ 1993-1996 5.8L E-Series ^ 2000-2002 6.8L Excursion ^ 1997-2002 6.8L E-Series, E-350 Chassis/RV/Cutaway ^ 1999-2002 6.8L Super Duty F-Series 250 HD/350/450/550 Motorhome ^ 1993-1998 7.5L All Vehicles NOTE FOR 1993 THROUGH 1998 MODEL YEAR FFV USE XO-10W30-FFV. NOTE THE "EXCEPTION 2001-2002 VEHICLES" SHOULD BE SERVICED WITH SAE 5W-30 MOTOR OIL Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 2767 Engine Oil: Technical Service Bulletins Motor Oil - Viscosity Grade Recommendation Article No. 99-8-16 05/03/99 MOTOR OIL - SAE VISCOSITY GRADE RECOMMENDATION - SERVICE TIP FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-1999 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-1999 CONTOUR LINCOLN-MERCURY: 1989-1992 MARK VII 1989-1994 TOPAZ 1989-1997 COUGAR 1989-1999 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1991-1994 CAPRI 1994-1998 MARK VIII 1995-1999 MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-1999 ECONOLINE, F-150, F-250 LD, RANGER 1991-1999 EXPLORER 1993-1999 VILLAGER 1995-1999 WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE Ford Motor Company now recommends SAE 5W-30 viscosity grade for servicing any Ford gasoline-powered vehicle regardless of model year. ACTION When servicing any Ford gasoline-powered vehicle, use SAE 5W-30 viscosity grade motor oil. Refer to the following text for further details. Both SAE 10W-30 and SAE 5W-30 viscosity grade motor oils have been recommended in the past depending on vehicle model and model year. Tests have proven SAE 5W-30 viscosity grade motor oil provides the optimum protection and benefits for Ford gasoline engines. At both high and low ambient temperature conditions, SAE 5W-30 provides the best overall protection. It allows faster starts under cold ambient temperatures. SAE 5W-30 also provides approximately 1/2% increase in fuel economy over SAE 10W-30. SAE 5W-30 viscosity grade motor oils certified for gasoline engines by the American Petroleum Institute (API) should be used for all service procedures requiring replacement of the motor oil. PART NUMBER PART NAME XO-5W30-QSP 5W-30 Motorcraft Super Premium Motor Oil OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 490000, 499000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil A/T Models .......................................................................................................................................... ............................................................. 6.3L (6.7 Qt) M/T Models .......................................................................................................................................... ............................................................ 6.0L (6.4 Qt) NOTE: Listed capacities are approximate. Check fluid level after filling. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 2770 Engine Oil: Fluid Type Specifications Engine Oil Type ................................................................................................................................... ............................................................... SAE 5W-20 NOTE: Refer to TSB# 02-1-9 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 2771 Engine Oil: Service Precautions SAFETY PRECAUTIONS WARNING: Prolonged and repeated contact with used engine oil may cause skin cancer. Avoid prolonged and repeated contact with oils, particularly used engine oils. - Wear protective clothing, including impervious gloves where practicable. - Do not put oily rags in pockets. - Avoid contaminating clothes, particularly underpants, with oil. - Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regularly. - First Aid treatment should be obtained immediately for open cuts and wounds. - Use barrier creams, applying them before each work period, to help the removal of oil from the skin. - Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have been removed. - Do not use gasoline, kerosine, diesel fuel, gas oil, thinner or solvents for cleaning skin. - If skin disorders develop, obtain medical advice without delay. - Where practicable, degrease components prior to handling. - Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Specifications Oil Cooler: Specifications Oil Cooler Assembly to Oil Filter Adapter Bolts 55-60 Nm Oil Cooler Insert 55-60 Nm Oil Cooler Bolt 55-60 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Specifications > Page 2775 Oil Cooler: Service and Repair Removal 1. Raise and support vehicle. 2. Remove the drain plug and drain the engine oil. 3. Drain the coolant. 4. On 44 vehicles equipped with 5.4L engines, loosen the bolt, and remove the oil cooler. 5. NOTE: Make sure all O-ring seals are in place. On 4x2 vehicles, remove the oil bypass filter. 6. On 4x2 vehicles, remove the oil cooler insert, and remove the oil cooler. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Specifications > Page 2776 7. Slide the hose clamps down and disconnect the coolant hoses from the oil cooler. 8. On 4x4 vehicles, remove the bolts and remove the oil cooler from the remote oil filter adapter. Installation 1. On 4x4 vehicles, position the remote oil filter adapter lines and install the nuts. 2. On 4x2 vehicles, position the coolant hoses and slide the hose clamps back. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Specifications > Page 2777 3. On 4x2 vehicles, install the oil cooler insert. 4. On 4x2 vehicles, install the oil bypass filter. 5. On 4x4 vehicles, position the oil cooler and install the bolt. 6. Install the drain plug. 7. Lower the vehicle. 8. Fill the engine with Ford Super Premium SAE 5W-30 Motor Oil X0-5W-30-QSP or equivalent meeting Ford specification WSS-M2C153-G. 9. Fill the engine coolant. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Specifications Oil Filter: Specifications Oil Filter 14-17 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Specifications Oil Filter Adapter: Specifications Oil Filter Adapter Bolt 20-30 Nm Nut 40-55 Nm Remote Oil Filter Adapter Line Bolts 25 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Oil Filter Adapter Oil Filter Adapter: Service and Repair Oil Filter Adapter Removal 1. Raise and support the vehicle. 2. Remove the lower radiator hose. 3. Remove the front drive axle assembly. 4. Remove the drain plug and drain the engine oil. 5. If the vehicle does have an oil cooler, remove the oil cooler. 6. Disconnect the oil pressure sender electrical connector. 7. On vehicles equipped with a remote oil filter adapter, remove the nuts and position the remote oil filter adapter aside. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Oil Filter Adapter > Page 2786 8. Remove the four bolts and the oil filter adapter. Installation 1. If equipped with a remote oil filter adapter, position the oil filter adapter and install the four bolts. - Install a new oil filter adapter gasket. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Oil Filter Adapter > Page 2787 2. Position the remote oil filter adapter and install the nuts. 3. On vehicles not equipped with a remote oil filter adapter, position the oil filter adapter and install the four bolts. - Install a new oil filter adapter gasket. - Position the oil filter adapter and install the four bolts. 4. Connect the oil pressure sender electrical connector. 5. If the vehicle is equipped with an oil cooler, install the oil cooler. 6. Install the drain plug. 7. Install the front drive axle assembly. 8. Install the lower radiator hose. 9. Lower the vehicle. 10. Fill the engine with Ford Super Premium SAE 5W-30 Motor Oil X0-5-W-30-QSP or equivalent meeting Ford specification WSS-M2C153-G. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Oil Filter Adapter > Page 2788 Oil Filter Adapter: Service and Repair Remote Adapter Removal 1. Raise and support the vehicle. 2. Remove the drain plug and drain the engine oil. 3. If equipped with an oil cooler, remove the two nuts and disconnect the remote oil filter adapter from the oil cooler. 4. If the vehicle is not equipped with an oil cooler, disconnect the oil pressure sender electrical connector. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Oil Filter Adapter > Page 2789 5. Remove the two nuts and disconnect the remote oil filter adapter. 6. Remove the oil filter. 7. Remove the bolts, and remove the remote oil filter adapter. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Oil Filter Adapter > Page 2790 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Oil Filter Adapter > Page 2791 1. Follow the removal procedure in reverse order. - Fill the engine with Ford Super Premium SAE 5W-30 Motor Oil X0-5W-30-QSP or equivalent meeting Ford specification WSS-M2C153-G. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Line, Engine > Component Information > Specifications Oil Line: Specifications Remote Oil Cooler Line to Cylinder Block 8-12 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Oil Pan Bolts Stage 1 2 Nm Stage 2 20 Nm Stage 3 Rotate 60 Degrees Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2798 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2799 Oil Pan: Service and Repair Removal 1. Raise and support the vehicle. 2. Remove the front drive axle assembly. 3. Remove the drain plug and drain the engine oil. 4. Remove the bolts. 5. NOTE: Be careful when removing the oil pan gasket. The oil pan gasket is reusable if it is not damaged. Remove the oil pan and oil pan gasket. Inspect oil pan gasket for damage. - Replace if necessary. Installation 1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. Clean the mating surfaces. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2800 2. NOTE: If the oil pan and the oil pan gasket are not secured within four minutes, the sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M513392-A. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply the silicone at the rear oil seal retainer to cylinder block sealing surface. Use Ford Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6. 3. NOTE: If the oil pan and the oil pan gasket are not secured within four minutes, the sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M513392-A. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply the silicone at the engine front cover to the cylinder block sealing surface. Use Ford Silicone Gasket and Sealant F4AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6. 4. Install the oil pan gasket and the oil pan and loosely install the 16 bolts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2801 5. NOTE: Make sure to tighten the bolts in three stages. Tighten the bolts in the sequence shown. Stage 1: Tighten to 2 Nm (18 inch lbs.). - Stage 2: Tighten to 20 Nm (15 ft. lbs.). - Stage 3: Tighten an additional 60°. 6. Install the front drive axle assembly. 7. Lower the vehicle. 8. Fill the engine with oil. - Use Ford Super Premium SAE 5W-30 Motor Oil X0-5W-30-QSP or equivalent meeting Ford specification WSS-M2C153-G. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Gauge: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference Oil Pressure Gauge: Customer Interest Oil Pressure Sending Unit - Drip Shield Interference Article No. 01-4-2 3/05/01 ENGINE - 5.4L - OIL SENDING UNIT INTERFERENCE FIT AT ENGINE OIL DRIP SHIELD - 4X4 VEHICLES EQUIPPED WITH 5.4L ENGINE ONLY FORD: 1998 F-250 LD 1998-2001 EXPEDITION, F-150 1999-2001 SUPER DUTY F SERIES LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit the engine oil sending unit contacting the oil drip shield attached to the front axle. This may be caused by tight tolerances between the engine oil sending unit and the engine oil drip shield. This may cause a malfunction of the engine oil sending unit. ACTION If the engine oil sending unit needs to be replaced due to contact with the drip shield, modify the engine oil drip shield as shown. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE IF THE ENGINE OIL SENDING UNIT NEEDS TO BE REPLACED IN SERVICE, MODIFY THE ENGINE OIL DRIP SHIELD BEFORE INSTALLING THE NEW ENGINE OIL SENDING UNIT. 1. Remove oil drip shield from front axle. This shield is attached to the front axle by three (3) bolts. 2. Modify shield as shown (Figure 1). Remove excess material from shield. Remove any sharp edges or burrs upon finishing cutting operation. 3. Reinstall engine oil drip shield. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Gauge: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference > Page 2810 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODE OASIS CODES: 401000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Gauge: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference Oil Pressure Gauge: All Technical Service Bulletins Oil Pressure Sending Unit - Drip Shield Interference Article No. 01-4-2 3/05/01 ENGINE - 5.4L - OIL SENDING UNIT INTERFERENCE FIT AT ENGINE OIL DRIP SHIELD - 4X4 VEHICLES EQUIPPED WITH 5.4L ENGINE ONLY FORD: 1998 F-250 LD 1998-2001 EXPEDITION, F-150 1999-2001 SUPER DUTY F SERIES LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit the engine oil sending unit contacting the oil drip shield attached to the front axle. This may be caused by tight tolerances between the engine oil sending unit and the engine oil drip shield. This may cause a malfunction of the engine oil sending unit. ACTION If the engine oil sending unit needs to be replaced due to contact with the drip shield, modify the engine oil drip shield as shown. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE IF THE ENGINE OIL SENDING UNIT NEEDS TO BE REPLACED IN SERVICE, MODIFY THE ENGINE OIL DRIP SHIELD BEFORE INSTALLING THE NEW ENGINE OIL SENDING UNIT. 1. Remove oil drip shield from front axle. This shield is attached to the front axle by three (3) bolts. 2. Modify shield as shown (Figure 1). Remove excess material from shield. Remove any sharp edges or burrs upon finishing cutting operation. 3. Reinstall engine oil drip shield. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Gauge: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference > Page 2816 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODE OASIS CODES: 401000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Technical Service Bulletins > Page 2817 Oil Pressure Gauge: Testing and Inspection Refer to Instrument Panel/Testing and Inspection/Procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Sender: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference Oil Pressure Sender: Customer Interest Oil Pressure Sending Unit - Drip Shield Interference Article No. 01-4-2 3/05/01 ENGINE - 5.4L - OIL SENDING UNIT INTERFERENCE FIT AT ENGINE OIL DRIP SHIELD - 4X4 VEHICLES EQUIPPED WITH 5.4L ENGINE ONLY FORD: 1998 F-250 LD 1998-2001 EXPEDITION, F-150 1999-2001 SUPER DUTY F SERIES LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit the engine oil sending unit contacting the oil drip shield attached to the front axle. This may be caused by tight tolerances between the engine oil sending unit and the engine oil drip shield. This may cause a malfunction of the engine oil sending unit. ACTION If the engine oil sending unit needs to be replaced due to contact with the drip shield, modify the engine oil drip shield as shown. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE IF THE ENGINE OIL SENDING UNIT NEEDS TO BE REPLACED IN SERVICE, MODIFY THE ENGINE OIL DRIP SHIELD BEFORE INSTALLING THE NEW ENGINE OIL SENDING UNIT. 1. Remove oil drip shield from front axle. This shield is attached to the front axle by three (3) bolts. 2. Modify shield as shown (Figure 1). Remove excess material from shield. Remove any sharp edges or burrs upon finishing cutting operation. 3. Reinstall engine oil drip shield. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Sender: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference > Page 2826 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODE OASIS CODES: 401000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Sender: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference Oil Pressure Sender: All Technical Service Bulletins Oil Pressure Sending Unit - Drip Shield Interference Article No. 01-4-2 3/05/01 ENGINE - 5.4L - OIL SENDING UNIT INTERFERENCE FIT AT ENGINE OIL DRIP SHIELD - 4X4 VEHICLES EQUIPPED WITH 5.4L ENGINE ONLY FORD: 1998 F-250 LD 1998-2001 EXPEDITION, F-150 1999-2001 SUPER DUTY F SERIES LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit the engine oil sending unit contacting the oil drip shield attached to the front axle. This may be caused by tight tolerances between the engine oil sending unit and the engine oil drip shield. This may cause a malfunction of the engine oil sending unit. ACTION If the engine oil sending unit needs to be replaced due to contact with the drip shield, modify the engine oil drip shield as shown. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE IF THE ENGINE OIL SENDING UNIT NEEDS TO BE REPLACED IN SERVICE, MODIFY THE ENGINE OIL DRIP SHIELD BEFORE INSTALLING THE NEW ENGINE OIL SENDING UNIT. 1. Remove oil drip shield from front axle. This shield is attached to the front axle by three (3) bolts. 2. Modify shield as shown (Figure 1). Remove excess material from shield. Remove any sharp edges or burrs upon finishing cutting operation. 3. Reinstall engine oil drip shield. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Sender: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference > Page 2832 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODE OASIS CODES: 401000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Technical Service Bulletins > Page 2833 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation Oil Pressure Warning Lamp/Indicator: Description and Operation The low oil pressure indicator on the instrument cluster receives the oil pressure status directly from the oil pressure switch. The two-position oil pressure gauge will display either normal or no oil pressure. The low oil pressure indicator will prove out when the ignition switch is placed in the START position and then in the RUN position. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation > Page 2837 Oil Pressure Warning Lamp/Indicator: Testing and Inspection Refer to Instrument Panel/Testing and Inspection/Procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Specifications Oil Pick Up/Strainer: Specifications Oil Pump Screen Cover and Tube Bolts 8-12 Nm Spacer 20-30 Nm Spacer Bolt 20-30 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Specifications > Page 2841 Oil Pick Up/Strainer: Service and Repair Removal 1. Remove the oil pan. 2. Remove the three (A) bolts and the (B) oil pump screen cover and tube. Installation 1. NOTE: Lubricate the new O-ring with Ford Super Premium SAE 5W-30 Motor Oil X0-5W-30-QSP or equivalent meeting Ford specification WSS-M2C153-G. Clean and inspect the mating surfaces and replace the O-ring. 2. Install the oil pump screen cover and tube and install the bolts. 3. Install the oil pan. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure Oil Pressure Pressure @ 1500rpm 20-44 psi Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications Intake Manifold: Specifications Throttle Body Fasteners 9 Nm Lower Intake Manifold to Upper Intake Manifold Bolts Stage 1 2 Nm Stage 2 8-12 Nm Upper Intake Manifold to Cylinder Head Bolts Stage 1 2 Nm Stage 2 20-30 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 2849 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal Intake Manifold: Service and Repair Removal WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions may result in personal injury. All Vehicles 1. Disconnect the battery ground cable. 2. Perform pre-service procedures. 3. Drain the cooling system. 4. Compress and slide the hose clamp and disconnect the upper radiator hose. 5. Remove the Engine Air Cleaner (ACL) and air cleaner outlet tube. 6. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the accelerator control splash shield. 7. Disconnect the accelerator cable from the accelerator cable bracket. 1 Remove the bolt. 2 Slide the accelerator cable up to remove it from the accelerator cable bracket. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2852 8. Disconnect the accelerator cable from the throttle body cam. 1 Roll the throttle body cam forward. 2 Slide the accelerator cable end from the throttle body cam. 9. Remove the throttle return spring. 10. If equipped, disconnect the speed control actuator cable from the throttle body. 1 Remove the speed control actuator cable to the bolt. 2 Disconnect the (A) speed control actuator cable from the (B) throttle body cam and position aside. 11. Disconnect the climate control vacuum hose. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2853 12. Remove the bolt and the brake booster vacuum hose and bracket. 13. Disconnect the connector from the Throttle Position (TP) sensor. 4.6L Engine 14. Disconnect the following throttle body hose connections: - vapor management hose (1) - Positive Crankcase Ventilation Valve (PCV valve) (2) - power brake booster (3) All Vehicles 15. On 4.6L engines, remove the (A) brake booster vacuum hose bracket nut from the (B) brake booster vacuum hose bracket. 16. Disconnect the fuel lines. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2854 17. Disconnect the PCV and PCV coolant hoses. 18. Disconnect the following electrical connectors: - Differential Pressure Feedback (DPFE) transducer - Engine Vacuum Regulator (EVR) sensor Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2855 19. Remove the EGR valve to exhaust manifold tube. - Disconnect the upper and lower EGR valve to exhaust manifold tube fittings. - Disconnect the two DPFE hoses. 4.6L Engine Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2856 5.4L Engine 20. Disconnect the following vacuum connections: 1 EGR vacuum hose 2 vacuum supply port 3 EVR vacuum hose 4 fuel pressure regulator vacuum hose All Vehicles 21. Disconnect the RH fuel injector electrical connectors. 22. Disconnect the LH fuel injector electrical connectors. 23. On 5.4L engines, disconnect and remove the eight ignition coils. 24. Remove the drive belt. 25. Remove the Generator (GEN). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2857 26. Remove the bolts and the throttle body. 27. Disconnect the hose clamp and remove the heater water hose. 28. Remove the studs. 29. Remove the water thermostat. 30. Remove the nine bolts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2858 31. Remove the upper intake manifold. 1 Lift the intake manifold. 2 Disconnect the Intake Manifold Tuning Valve (IMTV) connector. (4.6L engine and 5.4L NGV Only) 3 Remove and discard the upper intake manifold gaskets. 32. Remove the bolts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2859 33. Separate the upper intake manifold from the lower intake manifold and discard the lower intake manifold gasket. 34. Remove the (A) push pin from the (B) intake manifold insulator and remove from the (C) lower intake manifold. 35. Remove the (A) bolts from the (B) intake manifold tuning valve and remove the intake manifold tuning valve. (4.6L engine and 5.4L NGV only) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2860 Intake Manifold: Service and Repair Installation 1. Position the intake manifold tuning valve and install the bolts. (4.6L, engine and 5.4L NGV only) 2. Install the intake manifold insulator on the lower intake manifold and install the pushpin. 3. Position the lower intake manifold gasket and the upper intake manifold on the lower intake manifold and loosely install the eight bolts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2861 4. Tighten the bolts in two stages, in the sequence shown. Stage 1: 2 Nm (18 inch lbs.) Stage 2: 8-12 Nm (71-106 inch lbs.) 5. Install the studs. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2862 6. Install the upper intake manifold. - Position the upper intake manifold gaskets. - Position the upper intake manifold. - Loosely install the nine bolts. 7. Connect the intake manifold tuning valve connector.(4.6L engine and 5.4L NGV only) 8. Install the water thermostat. 9. Tighten the bolts in two stages, in the sequence shown. Stage 1: 2 Nm (18 inch lbs.) Stage 2: 20-30 Nm (15-22 ft. lbs.) 10. Position the throttle body onto the upper intake manifold and install the bolts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2863 11. Install the heater water hose and position the clamp. 12. Install the generator. 13. Install the drive belt. 14. On 5.4L engines, install the eight ignition coils. 15. Connect the LH fuel injector electrical connectors. 16. Connect the RH fuel injector electrical connectors. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2864 4.6L Engine 5.4L Engine 17. NOTE: For 4.6L engine-equipped vehicles, perform the following step. Connect the following vacuum connections: 1 EGR vacuum hose 2 vacuum supply port 3 EVR vacuum hose 4 fuel pressure regulator vacuum hose Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2865 18. Connect the EGR valve to exhaust manifold tube upper fitting. - On 4.6L engines, tighten both fittings starting at the top in two stages. Stage 1: Hand tighten. - Stage 2: Tighten to 35-45 Nm (26-33 ft. lbs.). - On 5.4L engines, tighten both fittings starting at the top in two stages. Stage 1: Hand tighten. - Stage 2: Tighten to 55-65 Nm (41-47 ft. lbs.). All Vehicles Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2866 19. Connect the following electrical connectors: - Differential Pressure Feedback (DPFE) transducer - Engine Vacuum Regulator (EVR) sensor 20. Connect the PCV and PCV coolant hoses. 21. On 4.6L engines, position the brake booster vacuum hose bracket and install the nut. 22. Connect the following electrical connectors: - DPFE transducer - engine vacuum regulator sensor 23. Connect the fuel lines. 24. Connect the climate control vacuum hose. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2867 25. Install the throttle return spring. 26. Connect the accelerator cable to throttle body cam. 1 Rotate the throttle body cam forward. 2 Slide the accelerator cable into the throttle body cam. 27. Connect the accelerator cable to accelerator cable bracket. 1 Slide the accelerator cable into the accelerator cable bracket. 2 Install the bolt. 28. Install the accelerator control splash shield. 29. Install the air cleaner outlet tube and the engine air cleaner. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Removal > Page 2868 30. Install the upper radiator hose and reposition the clamp. 31. Fill the cooling system. 32. Connect the battery ground cable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Gauge: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference Oil Pressure Gauge: Customer Interest Oil Pressure Sending Unit - Drip Shield Interference Article No. 01-4-2 3/05/01 ENGINE - 5.4L - OIL SENDING UNIT INTERFERENCE FIT AT ENGINE OIL DRIP SHIELD - 4X4 VEHICLES EQUIPPED WITH 5.4L ENGINE ONLY FORD: 1998 F-250 LD 1998-2001 EXPEDITION, F-150 1999-2001 SUPER DUTY F SERIES LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit the engine oil sending unit contacting the oil drip shield attached to the front axle. This may be caused by tight tolerances between the engine oil sending unit and the engine oil drip shield. This may cause a malfunction of the engine oil sending unit. ACTION If the engine oil sending unit needs to be replaced due to contact with the drip shield, modify the engine oil drip shield as shown. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE IF THE ENGINE OIL SENDING UNIT NEEDS TO BE REPLACED IN SERVICE, MODIFY THE ENGINE OIL DRIP SHIELD BEFORE INSTALLING THE NEW ENGINE OIL SENDING UNIT. 1. Remove oil drip shield from front axle. This shield is attached to the front axle by three (3) bolts. 2. Modify shield as shown (Figure 1). Remove excess material from shield. Remove any sharp edges or burrs upon finishing cutting operation. 3. Reinstall engine oil drip shield. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Gauge: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference > Page 2878 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODE OASIS CODES: 401000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Gauge: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference Oil Pressure Gauge: All Technical Service Bulletins Oil Pressure Sending Unit - Drip Shield Interference Article No. 01-4-2 3/05/01 ENGINE - 5.4L - OIL SENDING UNIT INTERFERENCE FIT AT ENGINE OIL DRIP SHIELD - 4X4 VEHICLES EQUIPPED WITH 5.4L ENGINE ONLY FORD: 1998 F-250 LD 1998-2001 EXPEDITION, F-150 1999-2001 SUPER DUTY F SERIES LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit the engine oil sending unit contacting the oil drip shield attached to the front axle. This may be caused by tight tolerances between the engine oil sending unit and the engine oil drip shield. This may cause a malfunction of the engine oil sending unit. ACTION If the engine oil sending unit needs to be replaced due to contact with the drip shield, modify the engine oil drip shield as shown. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE IF THE ENGINE OIL SENDING UNIT NEEDS TO BE REPLACED IN SERVICE, MODIFY THE ENGINE OIL DRIP SHIELD BEFORE INSTALLING THE NEW ENGINE OIL SENDING UNIT. 1. Remove oil drip shield from front axle. This shield is attached to the front axle by three (3) bolts. 2. Modify shield as shown (Figure 1). Remove excess material from shield. Remove any sharp edges or burrs upon finishing cutting operation. 3. Reinstall engine oil drip shield. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Gauge: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference > Page 2884 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODE OASIS CODES: 401000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Technical Service Bulletins > Page 2885 Oil Pressure Gauge: Testing and Inspection Refer to Instrument Panel/Testing and Inspection/Procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation Oil Pressure Warning Lamp/Indicator: Description and Operation The low oil pressure indicator on the instrument cluster receives the oil pressure status directly from the oil pressure switch. The two-position oil pressure gauge will display either normal or no oil pressure. The low oil pressure indicator will prove out when the ignition switch is placed in the START position and then in the RUN position. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation > Page 2889 Oil Pressure Warning Lamp/Indicator: Testing and Inspection Refer to Instrument Panel/Testing and Inspection/Procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > With Retainer Plate Crankshaft Main Bearing Seal: Service and Repair With Retainer Plate Special Tools Special Tools Removal 1. Remove the transmission. 2. Remove the oil pan. 3. Remove the flywheel. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > With Retainer Plate > Page 2895 4. Use the (A) Rear Crank Slinger Remover and the (B) Slide Hammer to remove the (C) rear oil seal slinger. 5. Use the (A) Rear Crankshaft Seal Remover and the (B) Slide Hammer to remove the (C) rear main seal. 6. If the oil dye leak test reveals a leak behind the retainer, remove the six bolts and the crankcase rear oil seal retainer. Installation 1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. NOTE: Clean sealing surfaces with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M513392-A. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer, failure to follow this procedure can cause future oil leakage. Clean and inspect the mating surface. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > With Retainer Plate > Page 2896 2. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. NOTE: If the rear crankshaft seal retaining plate is not secured within four minutes, the sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M513392-A. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. NOTE: The silicone must be applied on the groove along the retainer plate. Apply a 4 mm (0.16 inch) bead of silicone around the rear oil seal retainer sealing surface. Use Silicone Gasket and Sealant F4AZ-19562-A or equivalent meeting Ford specification WSE-M4G323-A6. 3. Install the rear oil seal retainer and loosely install the six bolts. 4. Tighten the bolts in the sequence shown. 5. NOTE: Lubricate the inner lip of the rear crankshaft seal with Super Premium 5W30 Motor Oil X0-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. Use the Rear Crankshaft Seal Replacer and the Rear Crankshaft Seal Adapter to install the rear main seal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > With Retainer Plate > Page 2897 6. With the Rear Crankshaft Seal Adapter still installed, use the Rear Crankshaft Slinger Replacer and the Rear Crankshaft Seal Replacer to install the rear main seal slinger. 7. Install the flywheel. 8. Install the oil pan. 9. Install the transmission. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > With Retainer Plate > Page 2898 Crankshaft Main Bearing Seal: Service and Repair Without Retainer Plate Special Tools Removal 1. Remove the transmission. 2. Remove the flywheel. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > With Retainer Plate > Page 2899 3. Use the (A) Rear Crankshaft Slinger Remover and the (B) Slide Hammer to remove the (C) rear oil seal slinger. 4. Use the (A) Rear Crankshaft Seal Remover and the (B) Slide Hammer to remove the (C) rear main seal. Installation 1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. NOTE: Lubricate the inner lip of the rear crankshaft seal with Super Premium 5W30 Motor Oil X0-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. Use the Rear Crankshaft Seal Replacer and the Rear Crankshaft Seal Adapter to install the rear main seal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > With Retainer Plate > Page 2900 2. With the Rear Crankshaft Seal Adapter still installed, use the Rear Crankshaft Slinger Replacer and the Rear Crankshaft Seal Replacer to install the rear main seal slinger. 3. Install the flywheel. 4. Install the transmission. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Page 2901 Crankshaft Main Bearing Seal: Tools and Equipment Special Tools Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Customer Interest: > 03-6-2 > Mar > 03 > Engine - Oil Leak From R/H Cylinder Head Gasket Cylinder Head Gasket: Customer Interest Engine - Oil Leak From R/H Cylinder Head Gasket Article No. 03-6-2 03/31/03 ENGINE - CYLINDER HEAD DECK LEAK - 4.6 AND 5.4L ENGINES - NEW "SERVICE-ONLY" GASKET AND CYLINDER HEAD KITS AVAILABILITY FORD: 1999-2002 CROWN VICTORIA, MUSTANG 1999-2001 E SERIES, EXPEDITION, F-150, SUPER DUTY F SERIES 2000-2001 EXCURSION LINCOLN: 1999-2002 TOWN CAR 1998-1999 NAVIGATOR MERCURY: 1999-2002 GRAND MARQUIS Article 02-22-7 is being republished in its entirety to update the Model Year and Model Line coverage. ISSUE Some vehicles equipped with the Romeo built 4.6L 2V engine or 5.4L 2V Windsor and 5.4L Supercharged engine may exhibit an oil leak or oil weepage from the cylinder head gasket at the right hand rear or the left hand front of the engine. Oil weepage is not considered detrimental to engine performance or durability. An oil leak may be caused by metal chip debris lodged between the head gasket and the block, chip debris between the cylinder head and the head gasket, or by damage to the cylinder head sealing surface that occurred during the manufacturing process. ACTION Once an oil leak is verified with a black light test at the head gasket joint, replacement of the head gasket can be performed. If the head was damaged by chip contamination, the head should be replaced. A revised "Service-Only" gasket is now released for both of these cases. SERVICE INFORMATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Customer Interest: > 03-6-2 > Mar > 03 > Engine - Oil Leak From R/H Cylinder Head Gasket > Page 2910 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Customer Interest: > 03-6-2 > Mar > 03 > Engine - Oil Leak From R/H Cylinder Head Gasket > Page 2911 Cylinder heads damaged by brinnelling (depression marks from original gasket) of the head may still be reusable. The revised "Service-Only" gasket has a feature by which the embossed sealing area does not follow the same sealing path as the original gasket. This area is surrounding the High Pressure Oil Feed (HPOF) area. It is triangular in shape and is found in the rear of the passenger side cylinder head, or, in the front of the drivers side cylinder head (Figure 1 and Figure 2). Required for service are: ^ A straightedge (machine flatness toleranced to 0.0002" per foot in length) (available from Snap-On or as provided by Ford Motor Company) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Customer Interest: > 03-6-2 > Mar > 03 > Engine - Oil Leak From R/H Cylinder Head Gasket > Page 2912 ^ Motorcraft Silicone Gasket Remover (ZC-30) ^ Metal Surface Prep (ZC-31) ^ Service-only gasket (3U7Z-6051-BA for drivers side and/or 3U7Z-6051-AA for passenger side) with the new embossed area The engine should be allowed to cool before removing the head or warpage may occur in deck flatness. The cylinder head and block decks should be cleaned before performing a flatness check. Dark metal stains below the surface of the metal are normal. Do not attempt to polish off the stains with grinders or scrapers. Use a plastic scraper (or plastic ice scraper or equivalent) to pull away any residual silicone RTV with ZC-30 and ZC-31 applied in sequence. The Workshop Manual and Service Labor Time Standards have been recently updated for both cars and truck using 4.6L 2V and 5.4L 2V and Supercharged 5.4L engines. These include instructions to remove the engine prior to removing the cylinder head. Service Labor Time Standards allow for extra time in engine removal and cylinder head deck leak repair out of vehicle. Cylinder Head Kits are available on most applications. Refer to the current Parts Catalog Listing for applicability. Cylinder Head Kits include: ^ Complete Head assembly, with Cam and Valves ^ Head Bolts ^ Service Only Head Gasket ^ Both Intake Gaskets Exhaust Gasket ^ One Rocker Cover Gasket ^ One set of Exhaust Studs and Nuts If it is found that only one head is leaking, it is not necessary to remove the other head Only repair the side for which leakage occurs. For detailed information on these subjects refer to previous articles on general cylinder head gasket repairs, machining of aluminum heads and blocks, gasket cleaners/removers, and straightedge procedures. Parts Block OTHER APPLICABLE ARTICLES: 01-12-2, 01-21-10, 02-1-4, 02-11-4, 02-21-13, 02-2-3, 02-17-2 SUPERSEDES: 02-22-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 402000, 403000, 490000, 497000, 499000 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Customer Interest: > 01-12-2 > Jun > 01 > Head Gasket - Right Hand Side Oil Leak Cylinder Head Gasket: Customer Interest Head Gasket - Right Hand Side Oil Leak Article No 01-12-2 06/25/01 ENGINE - OIL LEAK FROM RIGHT SIDE HEAD GASKET AREA - VEHICLES EQUIPPED WITH 4.6L/5.4L WINDSOR ENGINE ONLY - SERVICE TIPS FORD: 1999 E-150, E-250, EXPEDITION, F-150, F-250 LD, SUPER DUTY F SERIES LINCOLN: 1999 NAVIGATOR ISSUE On some vehicles there may be an oil leak from the right hand head gasket at the rear of the block/head joint. This may be caused by metal chip debris lodged between the head gasket and the block. ACTION Verify oil leak. Inspect for metal chips, impressions or dimples in the metal at the right bank cylinder head and block deck areas behind cylinder 4 at the area of the cast triangular recess in the cylinder head deck. Also inspect around the oil hole breakout in the block deck. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify the origin of the oil seep by adding fluorescent dye to the oil. Run the engine for 10 minutes and shut down. Start the engine after a 2 hour soak and run the engine for 10 minutes. Inspect the rear of the right hand cylinder head to block joint with an ultra-violet light ("black light") for oil stains and drips. 2. If the oil seep has been established as coming from the cylinder head to block joint, remove the cylinder head and head gasket per the Workshop Manual. 3. Clean both the block and cylinder head decks of residual gasket coating with Motorcraft Metal Surface Cleaner F4AZ-19A536-RA or equivalent. NOTE DO NOT USE A METAL TOOL OF ANY KIND ON THE GASKET SEALING SURFACE. RESULTING SCRATCHES WILL PROVIDE A LEAK PATH. USE PLASTIC OR WOOD SCRAPERS ONLY. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > Customer Interest: > 01-12-2 > Jun > 01 > Head Gasket - Right Hand Side Oil Leak > Page 2917 4. Inspect for the dimples and impressions. (Figures 1 and 2). 5. If no permanent damage to the block and cylinder head decks is found, replace the cylinder head gasket using current service replacement parts. 6. It damage is found, refer to the CYLINDER HEAD DECKS or CYLINDER BLOCK DECKS Instructions that follow. CYLINDER HEAD DECKS If such damage is spotted, check for flatness with a straight edge over the dimple or impression. If the dimple or impression on the head measures over .025 mm (.001 ") deep, the cylinder head, gasket and bolts should be replaced with new. Refer to the parts listing table that follows. CYLINDER BLOCK DECKS Check for flatness with a straight edge over the dimple or impression. If the dimple or impression measures over .025 mm (.001") deep, the engine should be replaced. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 40100, 499000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 06-18-16 > Sep > 06 > Engine - Reman Engine Head Gasket Identification Cylinder Head Gasket: All Technical Service Bulletins Engine - Reman Engine Head Gasket Identification TSB 06-18-16 09/18/06 IDENTIFYING THE CORRECT REPLACEMENT HEAD GASKET FOR CERTAIN REMANUFACTURED ENGINES - SERVICE TIP FORD: 1999-2006 Mustang, Mustang, Mustang, Mustang, Mustang, Mustang 2000-2005 Thunderbird 2001-2005 Taurus 2001-2006 Crown Victoria, Crown Victoria 2005 Five Hundred, Freestyle 1997-2005 Expedition 1997-2006 E-Series, Explorer, F-150, F-Super Duty 1999-2003 Windstar 1999-2004 F-53 Motorhome Chassis 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Escape, Escape, Explorer Sport Trac, Ranger 2004-2005 Freestar, Freestar 2006 F-53 Motorhome Chassis LINCOLN: 2000-2006 Lincoln LS 2001-2002 Continental 2001-200 Town Car 1998-2004 Navigator, Navigator 2003-2004 Aviator 2006 Mark LT MERCURY: 2001 Cougar 2001-2005 Sable 2001-2006 Grand Marquis 2003-2006 Marauder 2005 Montego 1997-2006 Mountaineer 2004-2005 Monterey 2005 Mariner ISSUE On various vehicles when servicing the head gasket on certain Ford remanufactured engines, it is critical to determine the type of remanufactured engine that is being serviced, in order to identify the correct replacement gasket. ACTION Follow the Service Procedure to help identify if the vehicle is equipped with a SID (for originally equipment level thickness head gasket) or OVR (for oversized service level thicker head gasket) remanufactured engine when replacing a head gasket. SERVICE PROCEDURE Use this TSB to help identify if the vehicle is equipped with a STD or OVR remanufactured engine when replacing a head gasket. This will ensure that you obtain the proper head gasket (thicker for OVR-oversized) for the engine you are repairing, as the engine may have milled engine block deck, milled cylinder head deck, or an over sized bore in the cylinders. This information will be needed when ordering parts. The parts catalogs already reflect the correct service numbers, as long as this additional information is available. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 06-18-16 > Sep > 06 > Engine - Reman Engine Head Gasket Identification > Page 2923 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 06-18-16 > Sep > 06 > Engine - Reman Engine Head Gasket Identification > Page 2924 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 06-18-16 > Sep > 06 > Engine - Reman Engine Head Gasket Identification > Page 2925 For certain remanufactured engines, the long block assembly will be uniquely identified with a build date, reman code, service part number, and serial number. This metal tag will be marked with STD, or with OVR (Figures 1-6). WARRANTY STATUS: Information Only Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 03-6-2 > Mar > 03 > Engine - Oil Leak From R/H Cylinder Head Gasket Cylinder Head Gasket: All Technical Service Bulletins Engine - Oil Leak From R/H Cylinder Head Gasket Article No. 03-6-2 03/31/03 ENGINE - CYLINDER HEAD DECK LEAK - 4.6 AND 5.4L ENGINES - NEW "SERVICE-ONLY" GASKET AND CYLINDER HEAD KITS AVAILABILITY FORD: 1999-2002 CROWN VICTORIA, MUSTANG 1999-2001 E SERIES, EXPEDITION, F-150, SUPER DUTY F SERIES 2000-2001 EXCURSION LINCOLN: 1999-2002 TOWN CAR 1998-1999 NAVIGATOR MERCURY: 1999-2002 GRAND MARQUIS Article 02-22-7 is being republished in its entirety to update the Model Year and Model Line coverage. ISSUE Some vehicles equipped with the Romeo built 4.6L 2V engine or 5.4L 2V Windsor and 5.4L Supercharged engine may exhibit an oil leak or oil weepage from the cylinder head gasket at the right hand rear or the left hand front of the engine. Oil weepage is not considered detrimental to engine performance or durability. An oil leak may be caused by metal chip debris lodged between the head gasket and the block, chip debris between the cylinder head and the head gasket, or by damage to the cylinder head sealing surface that occurred during the manufacturing process. ACTION Once an oil leak is verified with a black light test at the head gasket joint, replacement of the head gasket can be performed. If the head was damaged by chip contamination, the head should be replaced. A revised "Service-Only" gasket is now released for both of these cases. SERVICE INFORMATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 03-6-2 > Mar > 03 > Engine - Oil Leak From R/H Cylinder Head Gasket > Page 2930 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 03-6-2 > Mar > 03 > Engine - Oil Leak From R/H Cylinder Head Gasket > Page 2931 Cylinder heads damaged by brinnelling (depression marks from original gasket) of the head may still be reusable. The revised "Service-Only" gasket has a feature by which the embossed sealing area does not follow the same sealing path as the original gasket. This area is surrounding the High Pressure Oil Feed (HPOF) area. It is triangular in shape and is found in the rear of the passenger side cylinder head, or, in the front of the drivers side cylinder head (Figure 1 and Figure 2). Required for service are: ^ A straightedge (machine flatness toleranced to 0.0002" per foot in length) (available from Snap-On or as provided by Ford Motor Company) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 03-6-2 > Mar > 03 > Engine - Oil Leak From R/H Cylinder Head Gasket > Page 2932 ^ Motorcraft Silicone Gasket Remover (ZC-30) ^ Metal Surface Prep (ZC-31) ^ Service-only gasket (3U7Z-6051-BA for drivers side and/or 3U7Z-6051-AA for passenger side) with the new embossed area The engine should be allowed to cool before removing the head or warpage may occur in deck flatness. The cylinder head and block decks should be cleaned before performing a flatness check. Dark metal stains below the surface of the metal are normal. Do not attempt to polish off the stains with grinders or scrapers. Use a plastic scraper (or plastic ice scraper or equivalent) to pull away any residual silicone RTV with ZC-30 and ZC-31 applied in sequence. The Workshop Manual and Service Labor Time Standards have been recently updated for both cars and truck using 4.6L 2V and 5.4L 2V and Supercharged 5.4L engines. These include instructions to remove the engine prior to removing the cylinder head. Service Labor Time Standards allow for extra time in engine removal and cylinder head deck leak repair out of vehicle. Cylinder Head Kits are available on most applications. Refer to the current Parts Catalog Listing for applicability. Cylinder Head Kits include: ^ Complete Head assembly, with Cam and Valves ^ Head Bolts ^ Service Only Head Gasket ^ Both Intake Gaskets Exhaust Gasket ^ One Rocker Cover Gasket ^ One set of Exhaust Studs and Nuts If it is found that only one head is leaking, it is not necessary to remove the other head Only repair the side for which leakage occurs. For detailed information on these subjects refer to previous articles on general cylinder head gasket repairs, machining of aluminum heads and blocks, gasket cleaners/removers, and straightedge procedures. Parts Block OTHER APPLICABLE ARTICLES: 01-12-2, 01-21-10, 02-1-4, 02-11-4, 02-21-13, 02-2-3, 02-17-2 SUPERSEDES: 02-22-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 402000, 403000, 490000, 497000, 499000 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 02-1-4 > Jan > 02 > Engine Head Gasket - Approved Replacement Procedures Technical Service Bulletin # 02-1-4 Date: 020121 Engine Head Gasket - Approved Replacement Procedures Article No. 02-1-4 01/21/02 ENGINE - APPROVED HEAD GASKET REPLACEMENT SERVICE PROCEDURES FORD: 1992-1997 THUNDERBIRD 1992-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1995-2000 CONTOUR 2000-2002 FOCUS 1995-2002 WINDSTAR 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE LINCOLN: 1992-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1992-1997 COUGAR 1992-1999 TRACER 1992-2002 GRAND MARQUIS, SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER ISSUE Some engine assemblies with aluminum cylinder heads repaired in-vehicle have been found to leak coolant and/or oil from the cylinder head gasket area due to particle contamination or scratches and dents at the head to block mating surfaces. ACTION Refer to the following Service Information for recommended gasket sealing surface preparation procedures. If the engine diagnosis points to a faulty head gasket (leaks oil, leaks coolant, oil or coolant contamination, or air in coolant), thorough cleaning procedures are necessary for a successful head gasket repair. Diagnosis and post-repair confirmation can be done successfully utilizing leak detection methods such as a black light dye process. SERVICE PROCEDURE To sum up, a successful leak repair depends on: ^ Accurate diagnosis of the leak using Ford-recommended test equipment and procedures ^ Surface preparation and gasket installation using the approved tools, cleaners, and methods ^ Exercising CARE and CLEANLINESS during disassembly/assembly of components ^ Use of genuine Ford OEM replacement parts ^ Use of a Ford Remanufacturer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 402000, 403000, 499000 Aluminum Cylinder Head - Removal From Engine Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 02-1-4 > Jan > 02 > Engine Head Gasket - Approved Replacement Procedures > Page 2937 WARNING ALUMINUM CYLINDER HEADS ARE HIGHLY POLISHED AND MUST BE HANDLED WITH EXTREME CARE. AFTER REMOVING THE HEAD BOLTS, WITHDRAW THE HEAD FROM THE ENGINE COMPARTMENT. USE EXTREME CARE NOTING THAT THE GASKET SURFACE OF THE HEAD COULD BE DAMAGED ON THE WAY OUT OF THE VEHICLE IF ALLOWED TO HIT AGAINST OTHER ENGINE COMPONENTS. ONCE REMOVED, PLACE THE HEAD ON A BENCH, GASKET SIDE UP, USING A PIECE OF CLEAN CARDBOARD ON THE BENCH SURFACE UNDERNEATH. DO NOT SLIDE THE HEAD GASKET SURFACE ALONG THE BENCHTOP OR DAMAGE WILL OCCUR. NOTE SOME ENGINES REQUIRE A "DE-TORQUING" PROCEDURE OF THE CYLINDER HEAD BOLTS. CONSULT WITH THE APPROPRIATE MODEL YEAR WORKSHOP MANUAL FIRST, AS THIS PROCEDURE IS USUALLY DONE ON FOUR-VALVE ENGINES. HOWEVER, ALL ALUMINUM HEADS ARE PRONE TO WARPAGE DURING REMOVAL IF TAKEN OFF WHEN HOT OR WARM. THE ENGINE SHOULD BE COOLED SUFFICIENTLY BY THE TIME THE HEADS ARE ACCESSIBLE DURING TEARDOWN. ALLOW AN ADEQUATE COOL DOWN PERIOD. NOTE IN SOME ENGINE APPLICATIONS, IT MAY BE NECESSARY TO "RUBBER BAND" A FEW OF THE HEAD BOLTS TOGETHER DUE TO TIGHT CLEARANCES OF THE HEAD NEAR HEATER/AC PLENUMS AND THE BODY COWL. THIS WILL ALLOW THE BOLTS TO CLEAR THE BLOCK DECK AS THE HEAD IS WITHDRAWN FROM THE VEHICLE. Place CLEAN shop towels over the cylinder block bores to prevent further contamination from reaching internal parts and surfaces. If a towel is to be removed, do it SLOWLY . Debris collected on the towel can fall on the engine if care is not exercised as it is removed. Gasket surfaces are machined to near-mirror surface quality. Scratches, dents, gouges, and other impressions may allow oil, coolant, and compression gases to leak into other sealed cavities and/or the atmosphere. Surface imperfections deteriorate the head gasket's ability to seal effectively. Contamination on these surfaces will cause leaks from "shimming" the head even under full head bolt torque. Contamination will also cause marks on the polished gasket surface, creating a leak path. Inspection For Damage and Cleaning Procedure The overall straightness of the cylinder head and block face is held within very tight specification. Defects known as "waviness" or "depressions" cannot be surface machined out with ordinary equipment. Machining must meet manufacturer's specification on surface finish quality and be less than 0.001" inch (0.025 mm) level as measured under a known quality straightedge using a feeler gauge. If the engine has been overheated the cylinder head may have been damaged or warped. Re-surfacing will not correct this damage. The head must not contain any impressions on its sealing surface deeper than 0.001" (0.025 mm). There must not be any scratches or gouges present, especially those which track to another sealing cavity or to the atmosphere. Ensure that the mating cylinder block surface is completely free of solid contamination, corrosion, and fluids. Use Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA or equivalent, to rid the surface of any material, which could later interfere with the gasket's sealing ability. WARNING UNDER NO CIRCUMSTANCES ARE ANY ALUMINUM GASKET SURFACES TO BE CLEANED USING RAZOR BLADES, ROTARY ABRASIVE DEVICES INCLUDING ROLOC AND 3M BRANDED SCOTCHBRITE PRODUCTS, ROTARY WIRE BRUSHES, SINGLE HANDLED WIRE BRUSHES, HAND ABRASIVE SUCH AS SANDPAPER OR EMERY CLOTH, OR ANY CARBON STEEL BLADE. THESE TOOLS ARE PROVEN TO CUT AND DAMAGE ALUMINUM AND WILL DISRUPT THE POLISHED FINISH. ABRASIVE PARTICLES ARE ALSO SUSCEPTIBLE TO ENTERING THE ENGINE CAVITIES AND MAY CAUSE INTERNAL ENGINE DAMAGE. THE ONLY TOOLS ACCEPTABLE ARE PLASTIC AND WOOD SCRAPERS COMBINED WITH USE OF MOTORCRAFT METAL SURFACE CLEANER, F4AZ-19A536-RA, OR EQUIVALENT SOLVENT. The original head bolts are to be discarded. Only new head bolts are acceptable for use in a head gasket repair. Use of old bolts can cause clamp load failure because they were stretched from the last torquing procedure either from the plant or a previous field repair. The new head bolt shanks and threads should be thoroughly cleaned, dried, and lightly lubricated. Oil the bolts and let oil drip for a minimum of 5 minutes. Use of too much oil may cause hydraulic lockup in the bolt hole. The corresponding bolt holes in the cylinder block must be free of contamination consisting of dirt particles, coolant, and oil. Bolts can mechanically or hydraulically lock on top of these materials and cause for poor clamping of the cylinder head gasket. Use very lightly compressed air to blow out the bolt holes. Use care to prevent debris from scattering over the internal engine surfaces. To clean the cylinder block gasket surface, a plastic or wood scraper in combination with Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA, or equivalent solvent can be used with a portable shop vacuum. Move the scraper toward the vacuum nozzle to direct loosened material quickly away from the block surface. It is not necessary to expect aluminum head surfaces to be shiny and bright after the vehicle has been in service. Sanding, scraping, or polishing will create surface depressions that cause leaks. The surface is expected to be flat within 0.001" (0.025 mm) and free of dirt, metal chips, and liquid contaminants. Any staining of the metal surface is considered normal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 02-1-4 > Jan > 02 > Engine Head Gasket - Approved Replacement Procedures > Page 2938 Machining of aluminum heads and blocks is an unacceptable field practice for quality control purposes of flatness and surface finish standards. Removing material will also raise the risk of internal reciprocating components striking each other, as well as changing the emissions calibration of the engine. Machining practices of aluminum blocks and heads are not reimbursable. Ford Remanufacturers are authorized to perform this procedure and have the necessary equipment to put the specified surface finish on the head within original factory limits. Installation Onto the Cylinder Block Surface WARNING ANY GASKET SEALING AIDS WHICH ARE NOT LIMITED TO, AND INCLUDE AVIATION CEMENT, COPPER SPRAYS, OR GLUES ARE NOT TO BE USED. THE GASKET MUST BE FITTED DRY WITHOUT SUPPLEMENTAL SEALING AIDS. ATTEMPTS TO SEAL WITH THESE COMPOUNDS WILL CAUSE HEAD SHIMMING AND/OR NEW LEAK PATHS. THESE COMPOUNDS HAVE ALSO BEEN KNOWN TO CAUSE EMISSIONS SENSORS TO FAIL THEREBY TRIPPING FAULT CODES IN THE PCM. Ensure that all surfaces of the cylinder block, cylinder head, and gasket are fully free of any solid or liquid contamination and have been prepared for assembly using Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA, or equivalent solvent. Also ensure that any residual dirt on the engine was removed successfully from the surrounding areas of the block to head face of the head and the block. Using Workshop Manual procedures, assemble the head to the block carefully. Do not allow the gasket surfaces to scrape or bang against other engine parts. The head may pick up material along the way, if this is allowed. Once in place, with dowels properly aligned to the head and ensuring that the head is fully square, seated, and resting on the block deck in a level condition, install new "torque-to-yield" cylinder head bolts to a finger tight condition. Refer to the appropriate model year Workshop Manual for the procedure to torque the head bolts in the correct sequence and at the intervals specified. Failure to follow these instructions may result in a warped head, and damaged head bolt threads. Do not use "cheater pipes" on torque wrenches. Use a known quality, calibrated torque wrench. Pull evenly and steady on each bolt. Do not exert side pressures on the bolt hex, which can disrupt the integrity of the bolt head and give a false reading on the final torque value of the fastener. Once the engine is fully reassembled, be sure that fluid levels have been topped off as required for the operation. When the engine is ready for starting, ensure that the engine 6i1 pump is (was) primed properly and is in a "ready to start" condition with all engine oil galleys having been charged with oil. WARNING DO NOT RACE THE ENGINE UPON INITIAL STARTUP. MAINTAIN ENGINE IDLE TO BUILD OIL PRESSURE. USE OF A MECHANICAL PRESSURE GAUGE WILL ENSURE THAT OIL FLOW HAS DEVELOPED ON THE PUMP'S PRESSURE SIDE. A DEFECTIVE GAUGE OR LIGHT IN THE INSTRUMENT PANEL WILL NOT VERIFY PRESSURE HAS BEEN OBTAINED. SEVERE INTERNAL ENGINE DAMAGE WILL RESULT IF PRESSURE IS NOT OBSERVED AND STEADILY MAINTAINED. Allow a warm up period, which brings the engine to normal operating temperature. Check for leaks around the gasket joints of the head, front cover, and associated component parts. The vehicle should be road tested within normal guidelines to raise the engine to operating temperature and verify the repair is sound. Shut down the engine, allow for a cool-down and drain-back period to enable fluids to return to levels. Check fluid levels using owner guide recommendations (dipstick, sight gages, etc.). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 01-12-2 > Jun > 01 > Head Gasket - Right Hand Side Oil Leak Cylinder Head Gasket: All Technical Service Bulletins Head Gasket - Right Hand Side Oil Leak Article No 01-12-2 06/25/01 ENGINE - OIL LEAK FROM RIGHT SIDE HEAD GASKET AREA - VEHICLES EQUIPPED WITH 4.6L/5.4L WINDSOR ENGINE ONLY - SERVICE TIPS FORD: 1999 E-150, E-250, EXPEDITION, F-150, F-250 LD, SUPER DUTY F SERIES LINCOLN: 1999 NAVIGATOR ISSUE On some vehicles there may be an oil leak from the right hand head gasket at the rear of the block/head joint. This may be caused by metal chip debris lodged between the head gasket and the block. ACTION Verify oil leak. Inspect for metal chips, impressions or dimples in the metal at the right bank cylinder head and block deck areas behind cylinder 4 at the area of the cast triangular recess in the cylinder head deck. Also inspect around the oil hole breakout in the block deck. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify the origin of the oil seep by adding fluorescent dye to the oil. Run the engine for 10 minutes and shut down. Start the engine after a 2 hour soak and run the engine for 10 minutes. Inspect the rear of the right hand cylinder head to block joint with an ultra-violet light ("black light") for oil stains and drips. 2. If the oil seep has been established as coming from the cylinder head to block joint, remove the cylinder head and head gasket per the Workshop Manual. 3. Clean both the block and cylinder head decks of residual gasket coating with Motorcraft Metal Surface Cleaner F4AZ-19A536-RA or equivalent. NOTE DO NOT USE A METAL TOOL OF ANY KIND ON THE GASKET SEALING SURFACE. RESULTING SCRATCHES WILL PROVIDE A LEAK PATH. USE PLASTIC OR WOOD SCRAPERS ONLY. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cylinder Head Gasket: > 01-12-2 > Jun > 01 > Head Gasket - Right Hand Side Oil Leak > Page 2943 4. Inspect for the dimples and impressions. (Figures 1 and 2). 5. If no permanent damage to the block and cylinder head decks is found, replace the cylinder head gasket using current service replacement parts. 6. It damage is found, refer to the CYLINDER HEAD DECKS or CYLINDER BLOCK DECKS Instructions that follow. CYLINDER HEAD DECKS If such damage is spotted, check for flatness with a straight edge over the dimple or impression. If the dimple or impression on the head measures over .025 mm (.001 ") deep, the cylinder head, gasket and bolts should be replaced with new. Refer to the parts listing table that follows. CYLINDER BLOCK DECKS Check for flatness with a straight edge over the dimple or impression. If the dimple or impression measures over .025 mm (.001") deep, the engine should be replaced. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 40100, 499000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cylinder Head Gasket: > 06-18-16 > Sep > 06 > Engine - Reman Engine Head Gasket Identification Cylinder Head Gasket: All Technical Service Bulletins Engine - Reman Engine Head Gasket Identification TSB 06-18-16 09/18/06 IDENTIFYING THE CORRECT REPLACEMENT HEAD GASKET FOR CERTAIN REMANUFACTURED ENGINES - SERVICE TIP FORD: 1999-2006 Mustang, Mustang, Mustang, Mustang, Mustang, Mustang 2000-2005 Thunderbird 2001-2005 Taurus 2001-2006 Crown Victoria, Crown Victoria 2005 Five Hundred, Freestyle 1997-2005 Expedition 1997-2006 E-Series, Explorer, F-150, F-Super Duty 1999-2003 Windstar 1999-2004 F-53 Motorhome Chassis 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Escape, Escape, Explorer Sport Trac, Ranger 2004-2005 Freestar, Freestar 2006 F-53 Motorhome Chassis LINCOLN: 2000-2006 Lincoln LS 2001-2002 Continental 2001-200 Town Car 1998-2004 Navigator, Navigator 2003-2004 Aviator 2006 Mark LT MERCURY: 2001 Cougar 2001-2005 Sable 2001-2006 Grand Marquis 2003-2006 Marauder 2005 Montego 1997-2006 Mountaineer 2004-2005 Monterey 2005 Mariner ISSUE On various vehicles when servicing the head gasket on certain Ford remanufactured engines, it is critical to determine the type of remanufactured engine that is being serviced, in order to identify the correct replacement gasket. ACTION Follow the Service Procedure to help identify if the vehicle is equipped with a SID (for originally equipment level thickness head gasket) or OVR (for oversized service level thicker head gasket) remanufactured engine when replacing a head gasket. SERVICE PROCEDURE Use this TSB to help identify if the vehicle is equipped with a STD or OVR remanufactured engine when replacing a head gasket. This will ensure that you obtain the proper head gasket (thicker for OVR-oversized) for the engine you are repairing, as the engine may have milled engine block deck, milled cylinder head deck, or an over sized bore in the cylinders. This information will be needed when ordering parts. The parts catalogs already reflect the correct service numbers, as long as this additional information is available. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cylinder Head Gasket: > 06-18-16 > Sep > 06 > Engine - Reman Engine Head Gasket Identification > Page 2949 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cylinder Head Gasket: > 06-18-16 > Sep > 06 > Engine - Reman Engine Head Gasket Identification > Page 2950 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cylinder Head Gasket: > 06-18-16 > Sep > 06 > Engine - Reman Engine Head Gasket Identification > Page 2951 For certain remanufactured engines, the long block assembly will be uniquely identified with a build date, reman code, service part number, and serial number. This metal tag will be marked with STD, or with OVR (Figures 1-6). WARRANTY STATUS: Information Only Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cylinder Head Gasket: > 02-1-4 > Jan > 02 > Engine Head Gasket - Approved Replacement Procedures Technical Service Bulletin # 02-1-4 Date: 020121 Engine Head Gasket - Approved Replacement Procedures Article No. 02-1-4 01/21/02 ENGINE - APPROVED HEAD GASKET REPLACEMENT SERVICE PROCEDURES FORD: 1992-1997 THUNDERBIRD 1992-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1995-2000 CONTOUR 2000-2002 FOCUS 1995-2002 WINDSTAR 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE LINCOLN: 1992-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1992-1997 COUGAR 1992-1999 TRACER 1992-2002 GRAND MARQUIS, SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER ISSUE Some engine assemblies with aluminum cylinder heads repaired in-vehicle have been found to leak coolant and/or oil from the cylinder head gasket area due to particle contamination or scratches and dents at the head to block mating surfaces. ACTION Refer to the following Service Information for recommended gasket sealing surface preparation procedures. If the engine diagnosis points to a faulty head gasket (leaks oil, leaks coolant, oil or coolant contamination, or air in coolant), thorough cleaning procedures are necessary for a successful head gasket repair. Diagnosis and post-repair confirmation can be done successfully utilizing leak detection methods such as a black light dye process. SERVICE PROCEDURE To sum up, a successful leak repair depends on: ^ Accurate diagnosis of the leak using Ford-recommended test equipment and procedures ^ Surface preparation and gasket installation using the approved tools, cleaners, and methods ^ Exercising CARE and CLEANLINESS during disassembly/assembly of components ^ Use of genuine Ford OEM replacement parts ^ Use of a Ford Remanufacturer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 402000, 403000, 499000 Aluminum Cylinder Head - Removal From Engine Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cylinder Head Gasket: > 02-1-4 > Jan > 02 > Engine Head Gasket - Approved Replacement Procedures > Page 2956 WARNING ALUMINUM CYLINDER HEADS ARE HIGHLY POLISHED AND MUST BE HANDLED WITH EXTREME CARE. AFTER REMOVING THE HEAD BOLTS, WITHDRAW THE HEAD FROM THE ENGINE COMPARTMENT. USE EXTREME CARE NOTING THAT THE GASKET SURFACE OF THE HEAD COULD BE DAMAGED ON THE WAY OUT OF THE VEHICLE IF ALLOWED TO HIT AGAINST OTHER ENGINE COMPONENTS. ONCE REMOVED, PLACE THE HEAD ON A BENCH, GASKET SIDE UP, USING A PIECE OF CLEAN CARDBOARD ON THE BENCH SURFACE UNDERNEATH. DO NOT SLIDE THE HEAD GASKET SURFACE ALONG THE BENCHTOP OR DAMAGE WILL OCCUR. NOTE SOME ENGINES REQUIRE A "DE-TORQUING" PROCEDURE OF THE CYLINDER HEAD BOLTS. CONSULT WITH THE APPROPRIATE MODEL YEAR WORKSHOP MANUAL FIRST, AS THIS PROCEDURE IS USUALLY DONE ON FOUR-VALVE ENGINES. HOWEVER, ALL ALUMINUM HEADS ARE PRONE TO WARPAGE DURING REMOVAL IF TAKEN OFF WHEN HOT OR WARM. THE ENGINE SHOULD BE COOLED SUFFICIENTLY BY THE TIME THE HEADS ARE ACCESSIBLE DURING TEARDOWN. ALLOW AN ADEQUATE COOL DOWN PERIOD. NOTE IN SOME ENGINE APPLICATIONS, IT MAY BE NECESSARY TO "RUBBER BAND" A FEW OF THE HEAD BOLTS TOGETHER DUE TO TIGHT CLEARANCES OF THE HEAD NEAR HEATER/AC PLENUMS AND THE BODY COWL. THIS WILL ALLOW THE BOLTS TO CLEAR THE BLOCK DECK AS THE HEAD IS WITHDRAWN FROM THE VEHICLE. Place CLEAN shop towels over the cylinder block bores to prevent further contamination from reaching internal parts and surfaces. If a towel is to be removed, do it SLOWLY . Debris collected on the towel can fall on the engine if care is not exercised as it is removed. Gasket surfaces are machined to near-mirror surface quality. Scratches, dents, gouges, and other impressions may allow oil, coolant, and compression gases to leak into other sealed cavities and/or the atmosphere. Surface imperfections deteriorate the head gasket's ability to seal effectively. Contamination on these surfaces will cause leaks from "shimming" the head even under full head bolt torque. Contamination will also cause marks on the polished gasket surface, creating a leak path. Inspection For Damage and Cleaning Procedure The overall straightness of the cylinder head and block face is held within very tight specification. Defects known as "waviness" or "depressions" cannot be surface machined out with ordinary equipment. Machining must meet manufacturer's specification on surface finish quality and be less than 0.001" inch (0.025 mm) level as measured under a known quality straightedge using a feeler gauge. If the engine has been overheated the cylinder head may have been damaged or warped. Re-surfacing will not correct this damage. The head must not contain any impressions on its sealing surface deeper than 0.001" (0.025 mm). There must not be any scratches or gouges present, especially those which track to another sealing cavity or to the atmosphere. Ensure that the mating cylinder block surface is completely free of solid contamination, corrosion, and fluids. Use Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA or equivalent, to rid the surface of any material, which could later interfere with the gasket's sealing ability. WARNING UNDER NO CIRCUMSTANCES ARE ANY ALUMINUM GASKET SURFACES TO BE CLEANED USING RAZOR BLADES, ROTARY ABRASIVE DEVICES INCLUDING ROLOC AND 3M BRANDED SCOTCHBRITE PRODUCTS, ROTARY WIRE BRUSHES, SINGLE HANDLED WIRE BRUSHES, HAND ABRASIVE SUCH AS SANDPAPER OR EMERY CLOTH, OR ANY CARBON STEEL BLADE. THESE TOOLS ARE PROVEN TO CUT AND DAMAGE ALUMINUM AND WILL DISRUPT THE POLISHED FINISH. ABRASIVE PARTICLES ARE ALSO SUSCEPTIBLE TO ENTERING THE ENGINE CAVITIES AND MAY CAUSE INTERNAL ENGINE DAMAGE. THE ONLY TOOLS ACCEPTABLE ARE PLASTIC AND WOOD SCRAPERS COMBINED WITH USE OF MOTORCRAFT METAL SURFACE CLEANER, F4AZ-19A536-RA, OR EQUIVALENT SOLVENT. The original head bolts are to be discarded. Only new head bolts are acceptable for use in a head gasket repair. Use of old bolts can cause clamp load failure because they were stretched from the last torquing procedure either from the plant or a previous field repair. The new head bolt shanks and threads should be thoroughly cleaned, dried, and lightly lubricated. Oil the bolts and let oil drip for a minimum of 5 minutes. Use of too much oil may cause hydraulic lockup in the bolt hole. The corresponding bolt holes in the cylinder block must be free of contamination consisting of dirt particles, coolant, and oil. Bolts can mechanically or hydraulically lock on top of these materials and cause for poor clamping of the cylinder head gasket. Use very lightly compressed air to blow out the bolt holes. Use care to prevent debris from scattering over the internal engine surfaces. To clean the cylinder block gasket surface, a plastic or wood scraper in combination with Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA, or equivalent solvent can be used with a portable shop vacuum. Move the scraper toward the vacuum nozzle to direct loosened material quickly away from the block surface. It is not necessary to expect aluminum head surfaces to be shiny and bright after the vehicle has been in service. Sanding, scraping, or polishing will create surface depressions that cause leaks. The surface is expected to be flat within 0.001" (0.025 mm) and free of dirt, metal chips, and liquid contaminants. Any staining of the metal surface is considered normal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cylinder Head Gasket: > 02-1-4 > Jan > 02 > Engine Head Gasket - Approved Replacement Procedures > Page 2957 Machining of aluminum heads and blocks is an unacceptable field practice for quality control purposes of flatness and surface finish standards. Removing material will also raise the risk of internal reciprocating components striking each other, as well as changing the emissions calibration of the engine. Machining practices of aluminum blocks and heads are not reimbursable. Ford Remanufacturers are authorized to perform this procedure and have the necessary equipment to put the specified surface finish on the head within original factory limits. Installation Onto the Cylinder Block Surface WARNING ANY GASKET SEALING AIDS WHICH ARE NOT LIMITED TO, AND INCLUDE AVIATION CEMENT, COPPER SPRAYS, OR GLUES ARE NOT TO BE USED. THE GASKET MUST BE FITTED DRY WITHOUT SUPPLEMENTAL SEALING AIDS. ATTEMPTS TO SEAL WITH THESE COMPOUNDS WILL CAUSE HEAD SHIMMING AND/OR NEW LEAK PATHS. THESE COMPOUNDS HAVE ALSO BEEN KNOWN TO CAUSE EMISSIONS SENSORS TO FAIL THEREBY TRIPPING FAULT CODES IN THE PCM. Ensure that all surfaces of the cylinder block, cylinder head, and gasket are fully free of any solid or liquid contamination and have been prepared for assembly using Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA, or equivalent solvent. Also ensure that any residual dirt on the engine was removed successfully from the surrounding areas of the block to head face of the head and the block. Using Workshop Manual procedures, assemble the head to the block carefully. Do not allow the gasket surfaces to scrape or bang against other engine parts. The head may pick up material along the way, if this is allowed. Once in place, with dowels properly aligned to the head and ensuring that the head is fully square, seated, and resting on the block deck in a level condition, install new "torque-to-yield" cylinder head bolts to a finger tight condition. Refer to the appropriate model year Workshop Manual for the procedure to torque the head bolts in the correct sequence and at the intervals specified. Failure to follow these instructions may result in a warped head, and damaged head bolt threads. Do not use "cheater pipes" on torque wrenches. Use a known quality, calibrated torque wrench. Pull evenly and steady on each bolt. Do not exert side pressures on the bolt hex, which can disrupt the integrity of the bolt head and give a false reading on the final torque value of the fastener. Once the engine is fully reassembled, be sure that fluid levels have been topped off as required for the operation. When the engine is ready for starting, ensure that the engine 6i1 pump is (was) primed properly and is in a "ready to start" condition with all engine oil galleys having been charged with oil. WARNING DO NOT RACE THE ENGINE UPON INITIAL STARTUP. MAINTAIN ENGINE IDLE TO BUILD OIL PRESSURE. USE OF A MECHANICAL PRESSURE GAUGE WILL ENSURE THAT OIL FLOW HAS DEVELOPED ON THE PUMP'S PRESSURE SIDE. A DEFECTIVE GAUGE OR LIGHT IN THE INSTRUMENT PANEL WILL NOT VERIFY PRESSURE HAS BEEN OBTAINED. SEVERE INTERNAL ENGINE DAMAGE WILL RESULT IF PRESSURE IS NOT OBSERVED AND STEADILY MAINTAINED. Allow a warm up period, which brings the engine to normal operating temperature. Check for leaks around the gasket joints of the head, front cover, and associated component parts. The vehicle should be road tested within normal guidelines to raise the engine to operating temperature and verify the repair is sound. Shut down the engine, allow for a cool-down and drain-back period to enable fluids to return to levels. Check fluid levels using owner guide recommendations (dipstick, sight gages, etc.). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair Front Crankshaft Seal: Service and Repair Special Tools Removal 1. Remove the crankshaft pulley. 2. Use the (A) Front Cover Seal Remover to remove the (B) front cover seal. Installation 1. Lubricate the (A) and the (B) front oil seal inner lip. - Use Super Premium SAE 5W30 Motor Oil X0-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 2961 2. Use the (A) Crankshaft Seal Replacer/Cover Aligner to install the (B) into the (C). 3. Install the crankshaft pulley. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair > Page 2962 Special Tool Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair Valve Guide Seal: Service and Repair Special Tools Removal 1. Remove the valve springs. 2. Remove the valve stem seals. Installation 1. NOTE: The valve stem sea] must be bottomed on the valve seat. NOTE: Make sure that the garter spring is present in the valve stem seal. Use the (A) Valve Stem Seal Replacer to install the (B) valve stem seals. 2. Install the valve springs. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 2966 Special Tool Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Technical Service Bulletins > Customer Interest: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference Oil Pressure Sender: Customer Interest Oil Pressure Sending Unit - Drip Shield Interference Article No. 01-4-2 3/05/01 ENGINE - 5.4L - OIL SENDING UNIT INTERFERENCE FIT AT ENGINE OIL DRIP SHIELD - 4X4 VEHICLES EQUIPPED WITH 5.4L ENGINE ONLY FORD: 1998 F-250 LD 1998-2001 EXPEDITION, F-150 1999-2001 SUPER DUTY F SERIES LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit the engine oil sending unit contacting the oil drip shield attached to the front axle. This may be caused by tight tolerances between the engine oil sending unit and the engine oil drip shield. This may cause a malfunction of the engine oil sending unit. ACTION If the engine oil sending unit needs to be replaced due to contact with the drip shield, modify the engine oil drip shield as shown. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE IF THE ENGINE OIL SENDING UNIT NEEDS TO BE REPLACED IN SERVICE, MODIFY THE ENGINE OIL DRIP SHIELD BEFORE INSTALLING THE NEW ENGINE OIL SENDING UNIT. 1. Remove oil drip shield from front axle. This shield is attached to the front axle by three (3) bolts. 2. Modify shield as shown (Figure 1). Remove excess material from shield. Remove any sharp edges or burrs upon finishing cutting operation. 3. Reinstall engine oil drip shield. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Technical Service Bulletins > Customer Interest: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference > Page 2976 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODE OASIS CODES: 401000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference Oil Pressure Sender: All Technical Service Bulletins Oil Pressure Sending Unit - Drip Shield Interference Article No. 01-4-2 3/05/01 ENGINE - 5.4L - OIL SENDING UNIT INTERFERENCE FIT AT ENGINE OIL DRIP SHIELD - 4X4 VEHICLES EQUIPPED WITH 5.4L ENGINE ONLY FORD: 1998 F-250 LD 1998-2001 EXPEDITION, F-150 1999-2001 SUPER DUTY F SERIES LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit the engine oil sending unit contacting the oil drip shield attached to the front axle. This may be caused by tight tolerances between the engine oil sending unit and the engine oil drip shield. This may cause a malfunction of the engine oil sending unit. ACTION If the engine oil sending unit needs to be replaced due to contact with the drip shield, modify the engine oil drip shield as shown. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE IF THE ENGINE OIL SENDING UNIT NEEDS TO BE REPLACED IN SERVICE, MODIFY THE ENGINE OIL DRIP SHIELD BEFORE INSTALLING THE NEW ENGINE OIL SENDING UNIT. 1. Remove oil drip shield from front axle. This shield is attached to the front axle by three (3) bolts. 2. Modify shield as shown (Figure 1). Remove excess material from shield. Remove any sharp edges or burrs upon finishing cutting operation. 3. Reinstall engine oil drip shield. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference > Page 2982 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODE OASIS CODES: 401000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil Pressure Sender: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil Pressure Sender: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 2988 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil Pressure Sender: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 2989 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil Pressure Sender: > 99-12-4 > Jun > 99 > A/T - 4R70W 4-3 Coastdown Clunk Noise On Deceleration PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T - 4R70W 4-3 Coastdown Clunk Noise On Deceleration Article No. 99-12-4 06/14/99 ^ NOISE - "CLUNKING" HEARD DURING 4-3 COASTDOWN WHILE DECELERATING FROM 48-32 KM/H (30-20 MPH) - VEHICLES WITH 5.4L ENGINE AND 4R70W TRANSMISSION ^ TRANSMISSION - 4R7OW - 4-3 COASTDOWN "CLUNK" WHILE DECELERATING FROM 48-32 KM/H (30-20 MPH) - VEHICLES WITH 5.4L ENGINE LIGHT TRUCK: 1999 F-150 CALIBRATION 9VZA-AC CALIBRATION, 9VZA-AD CALIBRATION WARNING THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE(S). PERFORMING THIS MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS. ISSUE A 4-3 coastdown "clunk" when decelerating from 48-32 km/h (30-20 mph) may occur on some vehicles. This may be caused by the Powertrain Control Module (PCM) calibration. ACTION Follow normal diagnostic procedures per the 1999 F-150 Workshop Manual and reprogram the PCM. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991204A Reprogram Powertrain 0.4 Hr. Control Module (PCM) DEALER CODING CONDITION BASIC PART NO. CODE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil Pressure Sender: > 99-12-4 > Jun > 99 > A/T - 4R70W 4-3 Coastdown Clunk Noise On Deceleration > Page 2994 RECAL 42 OASIS CODES: 502000, 504000, 597997, 702200 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil Pressure Sender: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 3000 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil Pressure Sender: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 3001 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil Pressure Sender: > 99-12-4 > Jun > 99 > A/T - 4R70W 4-3 Coastdown Clunk Noise On Deceleration > Page 3006 RECAL 42 OASIS CODES: 502000, 504000, 597997, 702200 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Technical Service Bulletins > Page 3007 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft Sprocket Bolt M10 bolt: Tighten in two stages. Stage 1: Tighten to 40 Nm (30 ft.lbs.) Stage 2: Tighten an additional 90° M12 bolt: Tighten to 120 Nm (90 ft.lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Crankshaft Gear/Sprocket > Component Information > Specifications Crankshaft Gear/Sprocket: Specifications Crankshaft Pulley Bolt Stage 1 90 Nm (66.60 ft.lb) Stage 2 Loosen the bolt Stage 3 47-53 Nm (34-39 ft.lb) Stage 4 Additional 85-90 degrees Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Tools and Equipment Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Guide > Component Information > Specifications Timing Chain Guide: Specifications Timing Chain Guide Bolts 8-12 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Guide > Component Information > Specifications > Page 3021 Timing Chain Guide: Service and Repair For further information regarding this component, please refer to Timing Chain; Service and Repair. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner > Component Information > Specifications Timing Chain Tensioner: Specifications Timing Chain Hydraulic Tensioner Bolts 20-30 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair Timing Cover: Service and Repair Removal 1. Disconnect the battery ground cable. 2. Remove both of the valve covers. 3. Remove the radiator. 4. Remove the water pump. 5. Raise and support the vehicle. 6. Remove the top bolts and the lower bolt and position the power steering pump aside. 7. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 8. Remove the drain plug and drain the engine oil. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Page 3028 9. Remove the front bolts. 10. Remove the crankshaft front seal. 11. Lower the vehicle. 12. Disconnect the Camshaft Position (CMP) sensor electrical connection. 13. Remove the (A) bolt and the (B) belt idler pulley. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Page 3029 14. Remove the bolts. 15. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. Remove the engine front cover from the front cover to cylinder block dowel. Remove the engine front cover gasket and clean and inspect the mating surfaces. Installation 1. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the scaling surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. NOTE: If the engine front cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M513392-A. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Page 3030 NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before installation. Apply the silicone along the cylinder head to cylinder block surface and the oil pan to cylinder block surface. Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6. 2. Install the engine front cover with engine front cover gasket on the front cover to cylinder block dowel and loosely install the bolts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Page 3031 3. Tighten the engine front cover fasteners in sequence in two stages. Stage 1: Tighten fasteners 1-7 to 20-30 Nm (15-22 ft. lbs.). Stage 2: Tighten fasteners 6-15 to 40-55 Nm (30-41 ft. lbs.). 4. Position the (A) belt idler pulley and install the (B) bolt. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Page 3032 5. Connect the CMP electrical connection. 6. Raise and support the vehicle. 7. Install a new crankshaft front oil seal. 8. Loosely install the bolts, then tighten the bolts in the two stages following the sequence shown. - Stage 1: Tighten to 20 Nm (15 ft. lbs.). - Stage 2: Tighten an additional 60°. 9. Connect the crankshaft position sensor electrical connector. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Page 3033 10. NOTE: The front lower hole in the power steering pump is not used. Position the power steering pump and install the bolts. 11. Install the drain plug. 12. Lower the vehicle. 13. Install the valve covers. 14. Fill the engine with oil. - Use Ford Premium SAE 5W-30 Motor Oil X0-5W-30-QSP or equivalent meeting Ford specification WSS-M2C153-G. 15. Install the water pump. 16. Install the radiator. 17. Connect the battery ground cable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications Fuel Pressure Test Port: Specifications Fuel pressure relief valve 8 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 3039 Fuel Pressure Test Port: Service and Repair REMOVAL WARNING ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Release fuel pressure. 2. Remove the pressure relief valve. INSTALLATION 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > With 4R70W Idle Speed: Specifications With 4R70W Hot Idle ................................................................................................................................................ .................................................................. 720 RPM Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > With 4R70W > Page 3044 Idle Speed: Specifications With 4R100 Hot Idle ................................................................................................................................................ ......................................................... 760 - 830 RPM Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair REMOVAL 1. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the shield. 2. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. 3. Disconnect the (A) Positive Crankcase Ventilation (PCV) hose and the (B) Idle Air Control (IAC) valve inlet tube. 4. Loosen the clamps and remove the air cleaner outlet tube and resonator. INSTALLATION 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 3049 CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. NOTE: The inlet air cleaner has an alignment tab which fits into a slot on the outlet air cleaner. Make sure the tabs are aligned correctly. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair REMOVAL 1. Open the (A) air cleaner clamp and set the (B) outlet Air Cleaner (ACL) aside. 2. Remove the (A) Air Cleaner (ACL) element from the (B) open end of inlet. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. NOTE: The inlet air cleaner has an alignment tab which fits into a slot on the outlet air cleaner. Make sure tabs are aligned correctly. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Gauge Special Tool(s) WARNING - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the Schrader valve cap and install the Fuel Pressure Gauge. 2. Open the manual valve slowly on the Fuel Pressure Gauge and relieve the fuel pressure. - This will drain some fuel out of the system. Place the fuel in a suitable container. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications The RH (Passenger's) side ................................................................................................................. ................................................ Cylinders 1, 2, 3, and 4 The LH (Driver's side) .......................................................................................................................... ............................................. Cylinders 5, 6, 7 and 8 Firing Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Spark Plug: Specifications Spark Plug Gap 1.32-1.42 mm Spark Plugs 15 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap > Page 3068 Spark Plug: Specifications Spark Plug Gap 1.32-1.42 mm Spark Plugs 15 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3069 Spark Plug: Application and ID Original Spark Plug .............................................................................................................................. ............................................................... AWSF12E Replacement Spark Plug ................................... ................................................................................................................................................... AWSF12E Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3070 Spark Plug: Description and Operation The spark plug: ^ changes high-voltage pulses to sparks at gap which ignites fuel and air mixture. ^ originally equipped on the vehicle; has a platinum-enhanced active electrode for long life. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3071 Spark Plug: Service and Repair REMOVAL 1. Remove the Coil On Plug (COP). Remove the screw and the coil for each plug. NOTE: Remove any foreign debris from the spark plug wells with compressed air. 2. Remove the RH spark plugs. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3072 3. Remove the LH spark plugs. 4. Inspect the spark plugs for: - Deposits bridging spark plug gap (A). - Wet black deposits (oil fouling) (B). - Dry black deposits (carbon fouling) (C). - Overheating (D). - Deposits fused on spark plug (E). - Pre-ignition damage (F). - Normal spark plug (G). 5. Adjust the spark plug as required. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3073 INSTALLATION 1. Install the LH spark plugs. 2. Install the RH spark plugs. 3. Install the COPs. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Pressure Limit Chart Compression Pressure Limit Chart The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 3077 Compression Check: Testing and Inspection 1. Make sure the oil in the crankcase is of the correct viscosity and at the proper level and that the battery is properly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all the spark plugs. 2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the Compression Tester in the No. 1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, and using the auxiliary starter switch, crank the engine a minimum of five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Compression Pressure Limit Chart Compression Pressure Limit Chart The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. If one or more cylinders reads low, squirt approximately one tablespoon of Super Premium SAE 5W30 Motor Oil, X0-5W30-QSP meeting Ford specification WSS-M2C153-G on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. - If compression improves considerably, piston rings are faulty. - If compression does not improve, valves are sticking or seating improperly. - If two adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer does not indicate whether this vehicle has adjustable or non-adjustable valves. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump Bolts 20-30 Nm Water Pump Pulley Bolts 20-30 Nm Pump Pulley Ratio 1.3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 3084 Water Pump: Service and Repair Removal 1. Drain the cooling system. 2. Remove the engine cooling fan and fan shroud. 3. Remove the drive belt. 4. Remove the water pump pulley. 1 Remove the bolts. 2 Remove the water pump pulley. 5. On the 4.2L engine only, remove the upper radiator hose from the water pump. 6. Remove the water pump bolts. 7. Remove the (A) water pump from the (B) cylinder block. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 3085 - Clean and inspect the mating surfaces. Installation 1. Install the water pump. 1 Lubricate and install the O-ring seal. Use Premium Engine Coolant (green in color) E2FZ-19549-AA, E2FZ-19549-13, (in Oregon, F5FZ-19549-CC, in Canada, Motorcraft CXC-8-B) or equivalent meeting Ford specification ESE-M97B44-A. 2 Position the (A) water pump on the (B) engine. 3 Loosely install the bolts. 2. Tighten the bolts in the sequence shown. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 3086 3. Position the (A) water pump pulley on the (B) water pump and loosely install the bolts. 4. Tighten the bolts in the sequence shown. 5. Install upper radiator hose on water pump, 4.2L engine only. 6. Install the drive belt. 7. Install the engine cooling fan and fan shroud. 8. Fill the cooling system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations Coolant: Technical Service Bulletins Engine Coolant - Propylene Glycol Recommendations Article No. 01-23-6 11/26/01 ^ ENGINE COOLANT - PROPYLENE GLYCOL - FORD MOTOR COMPANY POSITION ON ENGINE COOLANTS MADE FROM PROPYLENE GLYCOL ^ ENGINE COOLANT - PROPYLENE GLYCOL-BASED - FORD MOTOR COMPANY POSITION ON PROPYLENE GLYCOL-BASED ENGINE COOLANTS FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2002 FOCUS 2002 THUNDERBIRD 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT 2000-2002 F-650, F-750 LINCOLN: 1989-1992 MARK VII 1989-2002 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1989-1994 TOPAZ 1989-1997 COUGAR 1989-2002 GRAND MARQUIS, SABLE 1991-1994 CAPRI 1991-1999 TRACER 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER MERKUR: 1989 SCORPIO, XR4TI This article is being republished in its entirety to update the model year coverage. ISSUE This TSB article describes Ford Motor Company's position on the use of propylene glycol-based engine coolants. ACTION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 3092 Ford Motor Company does not recommend nor endorse the use of engine coolants made with propylene glycol in Ford vehicles. Ford Motor Company currently recommends the use of ethylene glycol-based engine coolants. Published information suggests that engine coolants made with propylene glycol may provide engine cooling performance equivalent to engine coolants made with ethylene glycol. However, different brands of engine coolant provide varying corrosion protection for the cooling system. Ford does not have performance data for the multitude of engine coolants available in the aftermarket and therefore cannot recommend the use of any coolant except those sold by Ford Customer Service Division. Consult the vehicle's Owner's Guide to determine the appropriate Ford Customer Service Division coolant for the vehicle. Furthermore, claims of toxicological and environmental advantages of propylene glycol over ethylene glycol may be misleading. When significant new information is developed, Ford will review this policy. Ford Motor Company specifications recommend that vehicles be maintained using certain ethylene glycol-based engine coolants. Those specifications do not refer to engine coolants made with propylene glycol. Although the Ford New Vehicle Limited Warranty is not automatically voided upon the use of a coolant made with propylene glycol, if such use results in damage to the vehicle or its components, the cost of repairing the damage would not be covered by the Ford New Vehicle Limited Warranty. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-16-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity 19.4 qts .............................................................................................................................................................. ....................................... Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 3095 Coolant: Fluid Type Specifications Coolant Type ....................................................................................................................................... ................................ Ford Premium Engine Coolant Ford Specification................................................................................................................................. .........................................................ESE-M97B44-A Note: Use Ford Premium Engine Coolant (green in color). DO NOT USE Ford Extended LIfe Engine Coolant (orange in color). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Page 3096 Coolant: Service Precautions DO NOT mix green colored coolant with orange colored coolant. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Specifications Coolant Reservoir: Specifications Degas Bottle Bolts ............................................................................................................................... .......................................................... 9 Nm (80 lb in) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Specifications > Page 3100 Coolant Reservoir: Service and Repair Removal 1. Partially drain the cooling system. 2. Remove the degas bottle hose from the radiator. 1 Release the hose clamp and slide it away from the hose end. 2 Slide the overflow hose off the radiator fitting. 3. Disconnect the lower radiator hose from the degas bottle. 4. Remove the degas bottle. 1 Remove the degas bottle bolts. 2 Remove the degas bottle. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Specifications > Page 3101 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Specifications Fan Blade: Specifications Fan Clutch to Fan Bolts ....................................................................................................................... ......................................................... 17 Nm (13 lb ft) Fan Clutch to Water Pump .............................. ............................................................................................................................................. 55 Nm (41 lb ft) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Specifications > Page 3106 Fan Blade: Service and Repair Special Tools Removal WARNING: Do not run the engine while the protective components are removed. Failure to follow these instructions may result in personal injury. 1. Remove the air cleaner assembly. 2. Drain the cooling system. 3. Remove the front air deflector. 1 Remove the screws. 2 Remove the front air deflector. 4. Remove the upper hose from the radiator. 1 Release the clamp. 2 Disconnect the hose. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Specifications > Page 3107 5. Remove the degas bottle hose from the radiator. 1 Release the hose clamp and slide it away from the end of the hose. 2 Slide the overflow hose off the radiator fitting. 6. Remove the fan blade assembly and fan clutch. 1 Use the fan pulley holding wrench to hold the water pump pulley steady. 2 Use the fan clutch nut wrench to remove the fan blade and the fan clutch. 7. Remove the fan shroud. 1 Remove the screws. 2 Lift and remove the fan shroud. 8. Remove the fan blade and fan shroud out of the vehicle together. 9. Separate the fan clutch from the fan blade assembly. 1 Remove the bolts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Specifications > Page 3108 2 Separate the (A) fan blade assembly from the (B) fan clutch. Installation 1. Assemble the fan clutch to the fan blade assembly. 1 Position the fan clutch on the fan blade assembly. 2 Install the bolts. 2. Position the fan shroud and the fan blade assembly. 3. Install the fan shroud. 1 Lower the fan shroud onto the radiator clips. 2 Install the screws. 4. Install the fan blade assembly and fan clutch. 1 Position the fan blade assembly and fan clutch on the water pump pulley. 2 Use the fan clutch holding tool to hold the water pump pulley steady. 3 Use the fan clutch wrench to install the fan blade assembly and fan clutch. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Specifications > Page 3109 5. Connect the degas bottle hose to the radiator. 1 Push the overflow hose onto the radiator fitting. 2 Position and tighten the hose clamp. 6. Connect the upper radiator hose to the radiator. 1 Install the hose. 2 Connect the clamp. 7. Install the front air deflector. 1 Position the front air deflector. 2 Install the screws. 8. Fill the cooling system. 9. Install the air cleaner assembly. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Specifications > Page 3110 Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Specifications Fan Clutch: Specifications Fan Clutch to Fan Bolts 17 Nm Fan Clutch to Water Pump 55 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Specifications > Page 3114 Fan Clutch: Testing and Inspection Spin the fan blade by hand. A light resistance should be felt. If there is no resistance or very high resistance, the minimum and maximum fan speeds must be checked as follows: MINIMUM SPEED FAN CLUTCH REQUIREMENT TEST 1. Use a suitable marker to mark the water pump pulley, one of the fan blade bolts, and the crankshaft pulley. 2. Connect a tachometer to the engine. 3. Install a throttle adjusting tool. 4. Connect a digital photoelectric tachometer. 5. WARNING: To avoid the possibility of personal injury or damage to the vehicle, do not operate the engine until the fan blade has been first examined for possible cracks and separation. Failure to follow these instructions may result in personal injury. Start the engine and run it at approximately 1500 rpm until the normal operating temperature has been achieved. 6. Adjust the engine speed to 2300 rpm. 7. Adjust the strobe light to 3000 rpm and aim it at the water pump pulley. Adjust the engine speed until the light flash and the water pump pulley mark are synchronized. 8. Aim the strobe light at the fan blade retaining bolts. Adjust the strobe light until the light flash is synchronized with the marked fan blade retaining bolt (fan blade appears to stand still). 9. The fan blade speed must not be greater than 1500 rpm at 3000 water pump rpm. 10. Turn the engine off. 11. If the fan blade speed was greater than 1500 rpm, install a new fan clutch. MAXIMUM SPEED FAN CLUTCH REQUIREMENT TEST 1. Perform Steps 1 through 5 of the Minimum Speed Fan Clutch Requirement Test. 2. NOTE: The engine temperature should be above 96°C (205°F) for maximum fan speed. Block off areas on each side of the radiator in the engine compartment and the front of the radiator grille. This will raise the temperature of the air striking the fan clutch and should cause the fan to operate at maximum speed. 3. Place the climate control function selector switch in the MAX A/C position and the blower motor switch in the HI position. 4. Adjust the strobe light to 3000 rpm. 5. WARNING: To avoid the possibility of personal injury or damage to the vehicle, do not operate the engine until the fan blade has been first examined for possible cracks and separation. Failure to follow these instructions may result in personal injury. Start the engine and adjust the engine speed until the strobe light flash and the water pump pulley mark are synchronized. 6. Aim the strobe light at the fan blade retaining bolts. Adjust the strobe light until the light flash is synchronized with the marked fan blade retaining bolt (fan blade appears to stand still). 7. If the fan blade speed is less than 2300 rpm, install a new fan clutch. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Specifications > Page 3115 Fan Clutch: Service and Repair Special Tools Removal WARNING: Do not run the engine while the protective components are removed. Failure to follow these instructions may result in personal injury. 1. Remove the air cleaner assembly. 2. Drain the cooling system. 3. Remove the front air deflector. 1 Remove the screws. 2 Remove the front air deflector. 4. Remove the upper hose from the radiator. 1 Release the clamp. 2 Disconnect the hose. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Specifications > Page 3116 5. Remove the degas bottle hose from the radiator. 1 Release the hose clamp and slide it away from the end of the hose. 2 Slide the overflow hose off the radiator fitting. 6. Remove the fan blade assembly and fan clutch. 1 Use the fan pulley holding wrench to hold the water pump pulley steady. 2 Use the fan clutch nut wrench to remove the fan blade and the fan clutch. 7. Remove the fan shroud. 1 Remove the screws. 2 Lift and remove the fan shroud. 8. Remove the fan blade and fan shroud out of the vehicle together. 9. Separate the fan clutch from the fan blade assembly. 1 Remove the bolts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Specifications > Page 3117 2 Separate the (A) fan blade assembly from the (B) fan clutch. Installation 1. Assemble the fan clutch to the fan blade assembly. 1 Position the fan clutch on the fan blade assembly. 2 Install the bolts. 2. Position the fan shroud and the fan blade assembly. 3. Install the fan shroud. 1 Lower the fan shroud onto the radiator clips. 2 Install the screws. 4. Install the fan blade assembly and fan clutch. 1 Position the fan blade assembly and fan clutch on the water pump pulley. 2 Use the fan clutch holding tool to hold the water pump pulley steady. 3 Use the fan clutch wrench to install the fan blade assembly and fan clutch. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Specifications > Page 3118 5. Connect the degas bottle hose to the radiator. 1 Push the overflow hose onto the radiator fitting. 2 Position and tighten the hose clamp. 6. Connect the upper radiator hose to the radiator. 1 Install the hose. 2 Connect the clamp. 7. Install the front air deflector. 1 Position the front air deflector. 2 Install the screws. 8. Fill the cooling system. 9. Install the air cleaner assembly. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Tools and Equipment > Special Tools Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Tools and Equipment > Special Tools > Page 3121 Fan Clutch: Tools and Equipment Fan Clutch Holding Tool - Ast (8005) Fan Clutch Holding Tool AST tool# 8005 Allows the technician to hold the water pump pulleuy in place while loosening the radiator fan. 2009 Suggested user price: $41.20 Assenmacher Specialty Tools 1 800 525 2943 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor (ECT) 16-24 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications Engine Temperature Sensor: Specifications Cylinder Head Temperature (CHT) Sensor 6.9-13.5 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications > Page 3129 Engine Temperature Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Remove the Cylinder Head Temperature (CHT) sensor. 1 Disconnect the connector. 2 Remove the CHT sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications Temperature Sensor (Gauge): Specifications Temperature Sender 20 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications > Page 3133 Temperature Sensor (Gauge): Service and Repair Removal All Engines 1. Partially drain the cooling system. 4.6L Engines 2. Disconnect the connector and remove the water temperature indicator sender unit. 5.4L Engines 3. Disconnect the connector and remove the water temperature indicator sender unit. Installation 1. To install, reverse the removal procedure. - Fill the cooling system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Specifications Fan Shroud: Specifications Fan Shroud Bolts 8-10 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Specifications > Page 3137 Fan Shroud: Service and Repair Refer to Fan Blade for Service Procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3146 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3147 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3153 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3154 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 3155 Heater Core: Specifications Heater Core Bracket Screws ......................................................................................................................................................... 1.5-2.5 N.m (13-22 Lb-In) Heater Core Outlet Bracket Screws ............................................................................................................................................... 1.5-2.5 N.m (13-22 Lb-In) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 3156 Heater Core: Description and Operation The heater core consists of fins and tubes arranged to extract heat from the engine coolant and transfer it to air passing through the heater core. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 3157 Heater Core: Testing and Inspection HEATER CORE WARNING: CARBON MONOXIDE IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS NECESSARY TO OPERATE THE ENGINE WITH THE VEHICLE IN A CLOSED AREA SUCH AS A GARAGE, ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES OUTSIDE THE CLOSED AREA. 1. Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A coolant leak in the heater water hose could follow the heater core tube to the heater core and appear as a leak in the heater core. NOTE: Testing of returned heater cores reveals that a large percentage of heater cores are good and did not require replacement. If a heater core leak is suspected, the heater core must he tested by following the plugged heater core component test before the heater core pressure test. Perform a system inspection by checking the heater system thoroughly. 2. Check the integrity of the heater water hose clamps. NOTE: Spring-type clamps are installed as original equipment. Installation and overtightening of non-specification clamps can cause leakage at the heater water hose connection and damage the heater core. HEATER CORE - PLUGGED WARNING: THE HEATER CORE INLET HOSE WILL BECOME TOO HOT TO HANDLE IF THE SYSTEM IS WORKING CORRECTLY. 1. Check to see that the engine coolant is at the proper level. 2. Start the engine and turn on the heater. 3. When the engine coolant reaches operating temperature, feel the heater core outlet hose to see if it is hot. If it is not hot: the heater core may have an air pocket - the heater core may be plugged, or - the thermostat is not working properly. PRESSURE TEST Use the Radiator/Heater Core Pressure Tester to perform the pressure test. 1. Drain the coolant from the cooling system. NOTE: Due to space limitations, a bench test may be necessary for pressure testing. 2. Disconnect the heater water hoses from the heater core. 3. Install a short piece of heater water hose, approximately 101 mm (4 inches) long on each heater core tube. 4. Fill the heater core and heater water hoses with water and install Plug BT-7422-B and adapter BT-7422-A from the Radiator/Heater Core Pressure Tester in the heater water hose ends. Secure the heater water hoses, plug and adapter with hose clamps. 5. Attach the pump and gauge assembly from the Radiator/Heater Core Pressure Tester to the adapter. 6. Close the bleed valve at the base of the gauge. Pump 241 kpa (35 psi) of air pressure into the heater core. 7. Observe the pressure gauge for a minimum of three minutes. 8. If the pressure drops, check the heater water hose connections to the core tubes for leaks. If the heater water hoses do not leak, remove the heater core from the vehicle and perform the bench test. BENCH TEST 1. Remove the heater core from the vehicle. 2. Drain all of the coolant from the heater core. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 3158 3. Connect the 101 mm (4 inch) test heater water hoses with plug and adapter to the core tubes. Then connect the Radiator/Heater Core Pressure Tester to the adapter. 4. Apply 241 kPa (35 psi) of air pressure to the heater core. Submerge the heater core in water. 5. If a leak is observed, replace the heater core. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 3159 Heater Core: Service and Repair REMOVAL NOTE: If a heater core leak is suspected, the heater core must be leak-tested before it is removed from the vehicle. 1. Disconnect the battery. 2. Drain the cooling system. 3. Remove the instrument panel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 4. Compress the holding tabs and disconnect the heater water hoses at the heater core. See: Heater Hose/Service and Repair 5. Remove the A/C plenum demister adapter. 1 Remove the screw. 2 Remove the A/C plenum demister adapter. 6. Disconnect the vacuum line. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 3160 7. Remove the heater core bracket. 1 Remove the screws. 2 Remove the bracket. 8. Remove the plenum chamber top. 1 Remove the 13 screws. 2 Remove the plenum chamber top. 9. Remove the blend door assembly from the case. 10. Remove the heater core. INSTALLATION 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3169 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3170 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3176 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3177 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Technical Service Bulletins > Page 3178 Heater Hose: Specifications Hose Clamp ......................................................................................................................................... .......................................... 1.6-2.2 N.m (17-22 Lb-In) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Hose Couplings Heater Hose: Service and Repair Heater Hose Couplings Heater Hose Disconnect Tool SPECIAL TOOL(S) DISCONNECT 1. Depressurize the engine cooling system. WARNING: THE ENGINE MUST BE OFF, FULLY COOL AND THE COOLING SYSTEM FULLY DEPRESSURIZED BEFORE ATTEMPTING TO DISCONNECT ANY HEATER WATER HOSES. FAILURE TO COMPLY WITH THIS WARNING CAN RESULT IN SERIOUS INJURY OR BURNS FROM HOT LIQUID ESCAPING OUT OF THE ENGINE COOLING SYSTEM. 2. Push the heater water hose toward the tube to fully expose the locking tabs. 3. Push the Heater Hose Disconnect Tool over the coupling retainer windows to compress the retainer locking tabs. NOTE: When compressing the white coupling retainer, the Heater Hose Disconnect Tool must be perpendicular to and on the highest point of the coupling. 4. Pull the heater water hose away from the heater core tube. NOTE: A slight twisting motion while pulling on the heater water hose may be necessary to assist in the removal. 5. Plug the heater water hose. 6. Remove the white coupling retainer from the tube. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Hose Couplings > Page 3181 7. Spread the retainer tabs apart and slide the retainer off the tube. 8. Discard the retainer. CONNECT 1. Clean the tubes and lubricate with Ford Rubber Suspension Insulator Lube E25Y-19553-A or equivalent meeting Ford specification ESF-M99B112-A. 2. Install a new coupling retainer, spacer, and lubricated O-rings into the quick disconnect coupling housing. 3. Push the heater water hose with a quick disconnect coupling onto the tube. 4. Make sure the coupling is fully engaged by lightly pulling on the heater water hose. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Hose Couplings > Page 3182 Heater Hose: Service and Repair Removal and Installation REMOVAL 1. Drain the cooling system. 2. Disconnect the heater outlet hose at the engine. 3. Disconnect the heater inlet hose at the engine. 1 Loosen the hose clamp. 2 Disconnect the heater inlet hose. 4. Compress the holding tabs and disconnect the heater water hoses at the heater core. INSTALLATION 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation Engine coolant temperature information is received by the instrument cluster from the Powertrain Control Module (PCM) over the SCP network. Temperatures over 121°C (275°F) will display hot (H). If the engine coolant temperature data is missing or invalid for five seconds, the instrument cluster will move the engine coolant temperature gauge below the cold (C) position. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Description and Operation > Page 3187 Temperature Gauge: Testing and Inspection Refer to Instrument Panel/Testing and Inspection/Procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Customer Interest for Radiator: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator Radiator: Customer Interest A/T Cooler - Fluid Leaks at Radiator Article No. 00-9-1 DATE 5/1/00 TITLE LEAK - TRANSMISSION FLUID LEAKS AT RADIATOR - VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSION AND TRANSMISSION OIL COOLER IN RADIATOR END TANK FORD: 1997-2000 MUSTANG, EXPEDITION, EXPLORER, F-150, F-250 LD 1998-2000 RANGER 1999-2000 SUPER DUTY F SERIES LINCOLN: 1998-2000 NAVIGATOR MERCURY: 1998-2000 MOUNTAINEER This TSB is being republished in its entirety to update the vehicles affected and to update the Service Procedure. ISSUE Transmission fluid may leak between the radiator transmission oil cooler and the transmission oil cooler fitting (NOT the cooler line into the fitting), which may result in a residue of transmission fluid on the radiator tank around the transmission oil cooler fitting. This may be caused by insufficient thread sealer on the transmission oil cooler fitting. NOTE: THIS TSB DOES NOT APPLY TO TRANSMISSION FLUID LEAKAGE AT THE TRANSMISSION LINE TO TRANSMISSION OIL COOLER FITTING. ACTION Install O-ring W705181-S onto the transmission oil cooler fitting. The O-ring is designed to seal the leak and reduce the possibility of transmission fluid leakage. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify that transmission fluid is leaking between the transmission oil cooler and the transmission oil cooler fitting (NOT the transmission cooler line fitting into the transmission oil cooler fitting). Refer to Figure 1. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Customer Interest for Radiator: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 3196 2. Remove the radiator from the vehicle following Workshop Manual procedure. Place the radiator on a flat surface so that the transmission oil cooler fittings are facing upward. Refer to Figure 2. 3. Clean the area around the transmission oil cooler fitting. This will insure that contaminants do not enter the transmission oil cooler when the transmission oil cooler fittings are removed. CAUTION: OIL-BASED SOLVENTS AND CLEANERS SHOULD NOT BE USED WHEN CLEANING THE RADIATOR. OIL-BASED SOLVENTS AND CLEANERS CAN DAMAGE THE RADIATOR END TANK SEALS AND CAUSE LEAKS. 4. Remove the upper transmission oil cooler fitting. NOTE: REMOVE ONLY ONE (1) TRANSMISSION OIL COOLER FITTING AT A TIME, OTHERWISE THE COOLER MAY DROP INTO THE RADIATOR. 5. Once the fitting is removed from the transmission oil cooler, verify that there is a gasket between the transmission oil cooler and the inside of the radiator tank. If there is no gasket, replace the radiator. If the gasket is in place, continue to Step 6. 6. Inspect the transmission oil cooler fitting threads for damage. If the threads are damaged, replace the radiator. If the threads show no sign of damage, continue to Step 7. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Customer Interest for Radiator: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 3197 7. Install O-ring W705181-S on the transmission oil cooler fitting. Refer to Figures 2 and 3. CAUTION: THREAD SEALANT OR TAPE SHOULD NEVER BE USED ON THE THREADS OF THE TRANSMISSION OIL COOLER FITTING. THE USE OF SUCH MATERIALS WILL CREATE A LEAK PATH. 8. Making sure that the gasket between the transmission oil cooler and the inside of the radiator tank is still in place, reinstall the transmission oil cooler fitting. The fitting should be torqued to 38-45 N.m (28-33 lb-ft). NOTE:: DO NOT USE AIR TOOLS TO TORQUE THE TRANSMISSION OIL COOLER FITTING. USE A HAND-OPERATED TORQUE WRENCH ONLY. 9. Repeat Steps 2-8 for the other transmission oil cooler fitting. This fitting should also have the O-ring replaced even if it is not leaking. 10. Make sure that no radiator coolant has entered the transmission oil cooler. Reinstall the radiator in the vehicle following Workshop Manual procedure. 11. Verify that both the transmission and the engine cooling system have the proper fluid levels outlined in the Workshop Manual. PARTS INFORMATION LABOR OPERATION APPLICATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Customer Interest for Radiator: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 3198 OTHER APPLICABLE ARTICLES: NONE SUPERCEDES: 99-4-6 WARRANTY STATUS OPERATION DESCRIPTION DEALER CODING OASIS CODES: 402000, 510000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator Radiator: All Technical Service Bulletins A/T Cooler - Fluid Leaks at Radiator Article No. 00-9-1 DATE 5/1/00 TITLE LEAK - TRANSMISSION FLUID LEAKS AT RADIATOR - VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSION AND TRANSMISSION OIL COOLER IN RADIATOR END TANK FORD: 1997-2000 MUSTANG, EXPEDITION, EXPLORER, F-150, F-250 LD 1998-2000 RANGER 1999-2000 SUPER DUTY F SERIES LINCOLN: 1998-2000 NAVIGATOR MERCURY: 1998-2000 MOUNTAINEER This TSB is being republished in its entirety to update the vehicles affected and to update the Service Procedure. ISSUE Transmission fluid may leak between the radiator transmission oil cooler and the transmission oil cooler fitting (NOT the cooler line into the fitting), which may result in a residue of transmission fluid on the radiator tank around the transmission oil cooler fitting. This may be caused by insufficient thread sealer on the transmission oil cooler fitting. NOTE: THIS TSB DOES NOT APPLY TO TRANSMISSION FLUID LEAKAGE AT THE TRANSMISSION LINE TO TRANSMISSION OIL COOLER FITTING. ACTION Install O-ring W705181-S onto the transmission oil cooler fitting. The O-ring is designed to seal the leak and reduce the possibility of transmission fluid leakage. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify that transmission fluid is leaking between the transmission oil cooler and the transmission oil cooler fitting (NOT the transmission cooler line fitting into the transmission oil cooler fitting). Refer to Figure 1. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 3204 2. Remove the radiator from the vehicle following Workshop Manual procedure. Place the radiator on a flat surface so that the transmission oil cooler fittings are facing upward. Refer to Figure 2. 3. Clean the area around the transmission oil cooler fitting. This will insure that contaminants do not enter the transmission oil cooler when the transmission oil cooler fittings are removed. CAUTION: OIL-BASED SOLVENTS AND CLEANERS SHOULD NOT BE USED WHEN CLEANING THE RADIATOR. OIL-BASED SOLVENTS AND CLEANERS CAN DAMAGE THE RADIATOR END TANK SEALS AND CAUSE LEAKS. 4. Remove the upper transmission oil cooler fitting. NOTE: REMOVE ONLY ONE (1) TRANSMISSION OIL COOLER FITTING AT A TIME, OTHERWISE THE COOLER MAY DROP INTO THE RADIATOR. 5. Once the fitting is removed from the transmission oil cooler, verify that there is a gasket between the transmission oil cooler and the inside of the radiator tank. If there is no gasket, replace the radiator. If the gasket is in place, continue to Step 6. 6. Inspect the transmission oil cooler fitting threads for damage. If the threads are damaged, replace the radiator. If the threads show no sign of damage, continue to Step 7. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 3205 7. Install O-ring W705181-S on the transmission oil cooler fitting. Refer to Figures 2 and 3. CAUTION: THREAD SEALANT OR TAPE SHOULD NEVER BE USED ON THE THREADS OF THE TRANSMISSION OIL COOLER FITTING. THE USE OF SUCH MATERIALS WILL CREATE A LEAK PATH. 8. Making sure that the gasket between the transmission oil cooler and the inside of the radiator tank is still in place, reinstall the transmission oil cooler fitting. The fitting should be torqued to 38-45 N.m (28-33 lb-ft). NOTE:: DO NOT USE AIR TOOLS TO TORQUE THE TRANSMISSION OIL COOLER FITTING. USE A HAND-OPERATED TORQUE WRENCH ONLY. 9. Repeat Steps 2-8 for the other transmission oil cooler fitting. This fitting should also have the O-ring replaced even if it is not leaking. 10. Make sure that no radiator coolant has entered the transmission oil cooler. Reinstall the radiator in the vehicle following Workshop Manual procedure. 11. Verify that both the transmission and the engine cooling system have the proper fluid levels outlined in the Workshop Manual. PARTS INFORMATION LABOR OPERATION APPLICATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 3206 OTHER APPLICABLE ARTICLES: NONE SUPERCEDES: 99-4-6 WARRANTY STATUS OPERATION DESCRIPTION DEALER CODING OASIS CODES: 402000, 510000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Page 3207 Radiator: Specifications Radiator Pressure Test 138 kPa Radiator Draincock 0.7-1.4 Nm Radiator Support Bracket Bolts 30 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Page 3208 Radiator: Service and Repair Removal 1. Drain the engine cooling system. 2. Remove the fan. 3. On automatic transmission equipped vehicles, disconnect the transmission fluid cooler fitting. 1 Disconnect the upper transmission fluid cooler fitting. 2 Disconnect the lower transmission fluid cooler fitting. 4. Disconnect the lower radiator hose from the radiator. 5. Remove the radiator. 1 Remove the upper radiator support bracket bolts. 2 Remove the upper radiator support brackets and the jack handle and wheel nut wrench retainers. 3 Lift the radiator off the radiator mounting insulators. 4 Remove the radiator mounting insulators. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Component Information > Technical Service Bulletins > Page 3209 1. Install the radiator. 1 Install the radiator mounting insulators. 2 Position the radiator on the radiator mounting insulators. 3 Position the upper radiator support brackets and the jack handle retainers. 4 Install the bolts. 2. Connect the lower radiator hose to the radiator. 3. On automatic transmission equipped vehicles, connect the transmission fluid cooler lines. 1 Connect the lower transmission fluid cooler line. 2 Connect the upper transmission fluid cooler line. 4. Install the fan blade assembly. 5. Refill the engine cooling system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Specifications Radiator Cap: Specifications Pressure Relief Cap Opening Pressure 110 kPa Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Specifications > Page 3213 Radiator Cap: Testing and Inspection 1. WARNING: Never remove the pressure relief cap under any conditions while the engine is operating. Failure to follow these instructions could result in damage to the cooling system or engine or personal injury. To avoid having scalding hot coolant or steam blow out of the cooling system, never remove the pressure relief cap from a hot degas bottle. Wait until the engine has cooled, then wrap a thick cloth around the pressure relief cap and turn it slowly one turn (counterclockwise). Step back while the pressure is released from the cooling system. When certain all the pressure has been released, remove the pressure relief cap (still with a cloth). Inspect the pressure relief cap and seals for damage or deterioration. Replace the pressure relief cap if necessary. 2. Fit the pressure relief cap to Radiator/Heater Core Pressure Tester Kit using the aftermarket adapter. 3. NOTE: If the plunger of the pressure tester is depressed too fast, an incorrect pressure reading will result. Slowly pump the pressure tester until the pressure gauge stops increasing and note the highest pressure reading. Release pressure and repeat test. Install a new pressure relief cap if the pressure is not 99.3-121.4 kPa (14.4-17.6 psi). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Hoses (Lower) Radiator Hose: Service and Repair Radiator Hoses (Lower) Removal 1. Partially drain the cooling system. 2. Remove the outlet side of the air cleaner assembly. 3. Disconnect the lower radiator hose from the water pump. 4. Disconnect the lower radiator hose from the degas bottle. 5. Raise and support the vehicle. 6. Disconnect the lower radiator hose connections from the oil cooler. 7. Disconnect the lower radiator hose from the radiator. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Hoses (Lower) > Page 3218 8. Lower the vehicle. 9. Remove the lower radiator hose. Installation 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Radiator Hoses (Lower) > Page 3219 Radiator Hose: Service and Repair Radiator Hoses (Upper) Removal 1. Partially drain the cooling system. 2. Remove the upper radiator hose. 1 Release the hose clamps and slide them away from the hose ends. 2 Remove the upper radiator hose. Installation 1. Install the upper radiator hose. 1 Position the upper radiator hose. 2 Position and secure the hose clamps. 2. Fill the cooling system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor (ECT) 16-24 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications Engine Temperature Sensor: Specifications Cylinder Head Temperature (CHT) Sensor 6.9-13.5 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Specifications > Page 3228 Engine Temperature Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Remove the Cylinder Head Temperature (CHT) sensor. 1 Disconnect the connector. 2 Remove the CHT sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications Temperature Sensor (Gauge): Specifications Temperature Sender 20 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications > Page 3232 Temperature Sensor (Gauge): Service and Repair Removal All Engines 1. Partially drain the cooling system. 4.6L Engines 2. Disconnect the connector and remove the water temperature indicator sender unit. 5.4L Engines 3. Disconnect the connector and remove the water temperature indicator sender unit. Installation 1. To install, reverse the removal procedure. - Fill the cooling system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation Engine coolant temperature information is received by the instrument cluster from the Powertrain Control Module (PCM) over the SCP network. Temperatures over 121°C (275°F) will display hot (H). If the engine coolant temperature data is missing or invalid for five seconds, the instrument cluster will move the engine coolant temperature gauge below the cold (C) position. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Description and Operation > Page 3236 Temperature Gauge: Testing and Inspection Refer to Instrument Panel/Testing and Inspection/Procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications Thermostat Start to Open Temperature 86.7-90.6 C Thermostat Full Open Temperature 97.8-101.7 C Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Testing and Inspection > Thermostat Test Thermostat: Testing and Inspection Thermostat Test 1. Remove the water thermostat. 2. Check the water thermostat for seating. Hold the water thermostat up to a lighted background. Leakage of light around the thermostat valve at room temperature indicates that the water thermostat should be replaced. Some water thermostats have a small leakage notch at one location on the perimeter of the thermostat valve, which is considered normal. 3. Immerse it in a boiling antifreeze and water mixture. 4. For additional information, refer to Specifications for water thermostat opening temperature. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Testing and Inspection > Thermostat Test > Page 3242 Thermostat: Testing and Inspection Electrical Thermostat Test CAUTION: Always vent the exhaust to the outside when performing this test. NOTE: The electrical thermostat test is most accurate if performed indoors at less than 37.8°C (100°F) ambient air. This test may be performed with or without the hood open and with the engine warm or cold. 1. Check the engine coolant level. Fill as needed. 2. With the key OFF, remove the Engine Coolant Temperature (ECT) sensor harness connector and attach ECT Sensor "T" Cable as a jumper between the Powertrain Control Module (PCM) and the ECT Sensor. Attach 73 Digital Multimeter to the ECT Sensor "T" Cable. Voltage values (0 to 5 V) may now be monitored while the sensor retains its connection to the wiring harness. New Generation Star (NGS) Tester or the Service Bay Diagnostic System (SBDS) may be used to monitor the ECT on vehicles equipped with Data Link Connector (DLC). The SBDS sequence to use for the screen is: Tool box-Electronic Engine Control and DCL-Item. 3. NOTE: Running this test with the vehicle in gear or with the A/C compressor clutch engaged (running) will cause improper diagnosis. Place transmission in PARK (P) or NEUTRAL (N). 4. Start the engine and allow to idle throughout this test. Allow the engine to run for 2 minutes, then record the ECT voltage. Record the ECT voltage every 60 seconds. When the ECT voltage trend changes direction or only changes slightly (0.03 volts or less) from the previous reading, record this as the thermostat opening voltage. Use the voltage and corresponding coolant temperature chart. 5. If the thermostat opening voltage is greater than 0.75 volts and less than 82°C (180°F), install a new water thermostat. 6. If the thermostat opening voltage is less than 0.75 volts and greater than 82°C (180°F), the water thermostat is good and should not be replaced. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Testing and Inspection > Page 3243 Thermostat: Service and Repair Removal 1. Partially drain the cooling system. 2. Remove the upper radiator hose. 3. Remove the water outlet connection. 1 Remove the bolts. 2 Remove the water outlet connection. 4. Remove the (A) water thermostat and the (B) O-ring. - Discard the (B) O-ring. Installation 1. Use a new (A) O-ring to position the (B) water thermostat in the (C) upper intake manifold. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Testing and Inspection > Page 3244 2. Install the water outlet connection and the bolts. 3. Connect the upper radiator hose. 4. Fill the cooling system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling > Component Information > Specifications Thermostat Housing: Specifications water Outlet Connection Bolts 25 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump Bolts 20-30 Nm Water Pump Pulley Bolts 20-30 Nm Pump Pulley Ratio 1.3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 3251 Water Pump: Service and Repair Removal 1. Drain the cooling system. 2. Remove the engine cooling fan and fan shroud. 3. Remove the drive belt. 4. Remove the water pump pulley. 1 Remove the bolts. 2 Remove the water pump pulley. 5. On the 4.2L engine only, remove the upper radiator hose from the water pump. 6. Remove the water pump bolts. 7. Remove the (A) water pump from the (B) cylinder block. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 3252 - Clean and inspect the mating surfaces. Installation 1. Install the water pump. 1 Lubricate and install the O-ring seal. Use Premium Engine Coolant (green in color) E2FZ-19549-AA, E2FZ-19549-13, (in Oregon, F5FZ-19549-CC, in Canada, Motorcraft CXC-8-B) or equivalent meeting Ford specification ESE-M97B44-A. 2 Position the (A) water pump on the (B) engine. 3 Loosely install the bolts. 2. Tighten the bolts in the sequence shown. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 3253 3. Position the (A) water pump pulley on the (B) water pump and loosely install the bolts. 4. Tighten the bolts in the sequence shown. 5. Install upper radiator hose on water pump, 4.2L engine only. 6. Install the drive belt. 7. Install the engine cooling fan and fan shroud. 8. Fill the cooling system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Exhaust System - Catalytic Converter Ticking/Knocking Catalytic Converter: Technical Service Bulletins Exhaust System - Catalytic Converter Ticking/Knocking TSB 04-20-6 10/18/04 TICKING OR KNOCKING NOISE COMING FROM THE CATALYTIC CONVERTERS FORD: 1997-1998 F-250 LD 1997-2003 F-150 ISSUE Some 1997-2003 F-150 vehicles equipped with any engine, and 1997-1998 F-250 LD vehicles equipped with the 5.4L engine, may exhibit a ticking or knocking noise coming from the catalytic converters. The noise may be described as sounding like a diesel engine. The condition will be present when the vehicle is in gear at idle only, and is more pronounced when the vehicle is stationary, such as sitting in a drive-through line. The noise is normal, and is created by engine pulses being amplified through the light-off converters. ACTION DO NOT replace converters unless loose internal components are found. To reduce the noise, install a wrap kit on each of the light-off converters. Refer to the instruction sheet included in the kit. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage Parts Block OPERATION DESCRIPTION TIME 042006A Install Wrap Kit On Both 0.7 Hr. Light-Off Converters (Includes Time To Perform Road Test) DEALER CODING CONDITION BASIC PART NO. CODE 5E212 42 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Exhaust System - Catalytic Converter Ticking/Knocking > Page 3259 Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Exhaust System - Catalytic Converter Ticking/Knocking > Page 3260 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Exhaust System - Catalytic Converter Ticking/Knocking > Page 3261 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Exhaust System - Catalytic Converter Ticking/Knocking > Page 3262 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Exhaust System - Catalytic Converter Ticking/Knocking > Page 3263 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Exhaust System - Catalytic Converter Ticking/Knocking > Page 3264 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Exhaust System - Catalytic Converter Ticking/Knocking > Page 3265 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Exhaust System - Catalytic Converter Ticking/Knocking > Page 3266 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Exhaust System - Catalytic Converter Ticking/Knocking > Page 3267 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Exhaust System - Catalytic Converter Ticking/Knocking > Page 3268 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Exhaust System - Catalytic Converter Ticking/Knocking > Page 3269 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Exhaust System - Catalytic Converter Ticking/Knocking > Page 3270 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Exhaust System - Catalytic Converter Ticking/Knocking > Page 3271 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Exhaust System - Catalytic Converter Ticking/Knocking > Page 3272 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Exhaust System - Catalytic Converter Ticking/Knocking > Page 3273 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Exhaust System - Catalytic Converter Ticking/Knocking > Page 3274 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3275 Catalytic Converter: Specifications Three Way Catalytic Converter to Exhaust Manifold Nuts 34-46 Nm Exhaust Converter Frame Bracket to Catalytic Converter Pipe Nuts 34-46 Nm LH to RH Catalytic Converter Pipe Clamp Nuts 47-63 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3276 Catalytic Converter: Service and Repair Removal 1. Remove the muffler and tail pipe assembly. 2. NOTE: On the 4.2L engine, the two upstream Heated Oxygen Sensors (H02S) are located on the exhaust manifolds and do not need to be removed. Disconnect the H02S and the catalyst monitor sensor. 3. Remove the nuts. 4. Remove the transfer case skid plate, if equipped. 1 Remove the bolts. 2 Remove the transfer case skid plate. 5. Remove the two bolts retaining the heat shield to the transmission support crossmember bolts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3277 6. Use a High-Lift jack to support the transmission. 7. Remove the nuts. 8. Remove the transmission support crossmember. 1 Remove the bolts. 2 Remove the transmission support crossmember. 9. On 4.2L or 4.6L engine, remove the nuts. 10. On 5AL engine, remove the nuts. 11. Remove the two TWCs. 1 For 4.2L or 4.6L engine, perform Steps 12 and 13. 2 For 5.4L engine, perform Steps 14 and 15. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3278 12. On 4.2L and 4.6L engine, if only one TWC is being replaced, remove the LH to RH TWC clamp. 13. NOTE: It may be necessary to heat the LH to RH three way catalytic converter joint to ease removal. Separate the LH and RH TWCs. 14. On 5.4L, engine, if only one TWC is being replaced, remove the clamp. 15. NOTE: It may be necessary to heat the LH to RH three way catalytic converter joint to ease removal. Separate the LH and RH TWCs. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3279 1. Insert the LH TWC into the RH TWC. 2. On 5AL engine, insert the LH TWC into the RH TWC. 3. On 5.4L engine, install the pipe clamp. - Install the nuts. 4. Position the RH and LH TWCs and install the nuts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3280 5. Install the LH to RH three way catalytic converter pipe clamp. - Install the two nuts. - The 4.2L and 4.6L, components are shown; the 5.4L system is similar. 6. On 4.2L and 4.6L engine, install the nuts. 7. On 5.4L engine, install the nuts. 8. Install the transmission support crossmember. 1 Position the transmission support crossmember. 2 Install the bolts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Technical Service Bulletins > Page 3281 9. Install the nuts. 10. Install the heat shield to crossmember bolts. 11. Remove the High-Lift Jack. 12. Connect the heated oxygen sensor and the two catalyst monitor sensor electrical connectors. 13. Install the transfer case skid plate. 1 Position the transfer case skid plate. 2 Install the bolts. 14. Install the muffler and tailpipe. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Technical Service Bulletins > Customer Interest for Exhaust Manifold: > 09-22-8 > Nov > 09 > Exhaust System - Broken Exhaust Manifold Studs Exhaust Manifold: Customer Interest Exhaust System - Broken Exhaust Manifold Studs TSB 09-22-8 11/16/09 STAINLESS STEEL EXHAUST STUDS - 5.4L AND 6.8L 2V ENGINES FORD: 1997-2004 Expedition, F-150 1999-2010 E-Series, F-Super Duty 2000-2005 Excursion LINCOLN: 1998-1999 Navigator This article supersedes TSB 5-5-4 to update the vehicle model years and engine application. ISSUE Some 1997-2010 F-Series, 1999-2010 E-Series, 2000-2005 Excursion, 1997-2004 Expedition and 1998-1999 Navigators equipped with the 5.4L or 6.8L 2-valve (non supercharged) engine, may exhibit broken exhaust manifold studs. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Refer to Workshop Manual, Section 303-01 for exhaust manifold removal and installation for the affected engine bank only. 1. Replace exhaust manifold. 2. Replace manifold gasket. 3. Install all new stainless steel exhaust manifold studs and nuts. 4. Torque the studs in the cylinder head to 71-115 lb-in (8-13 N.m). 5. Torque nuts on studs to 204-239 lb-in (23-27 N.m). Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT092208 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 9430 24 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Technical Service Bulletins > Customer Interest for Exhaust Manifold: > 09-22-8 > Nov > 09 > Exhaust System - Broken Exhaust Manifold Studs > Page 3290 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Manifold: > 09-22-8 > Nov > 09 > Exhaust System Broken Exhaust Manifold Studs Exhaust Manifold: All Technical Service Bulletins Exhaust System - Broken Exhaust Manifold Studs TSB 09-22-8 11/16/09 STAINLESS STEEL EXHAUST STUDS - 5.4L AND 6.8L 2V ENGINES FORD: 1997-2004 Expedition, F-150 1999-2010 E-Series, F-Super Duty 2000-2005 Excursion LINCOLN: 1998-1999 Navigator This article supersedes TSB 5-5-4 to update the vehicle model years and engine application. ISSUE Some 1997-2010 F-Series, 1999-2010 E-Series, 2000-2005 Excursion, 1997-2004 Expedition and 1998-1999 Navigators equipped with the 5.4L or 6.8L 2-valve (non supercharged) engine, may exhibit broken exhaust manifold studs. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Refer to Workshop Manual, Section 303-01 for exhaust manifold removal and installation for the affected engine bank only. 1. Replace exhaust manifold. 2. Replace manifold gasket. 3. Install all new stainless steel exhaust manifold studs and nuts. 4. Torque the studs in the cylinder head to 71-115 lb-in (8-13 N.m). 5. Torque nuts on studs to 204-239 lb-in (23-27 N.m). Parts Block WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part. OPERATION DESCRIPTION TIME MT092208 Use SLTS Operations If Actual Available; Claim Additional Time Diagnosis Or Labor Performed As Actual Time DEALER CODING CONDITION BASIC PART NO. CODE 9430 24 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Manifold: > 09-22-8 > Nov > 09 > Exhaust System Broken Exhaust Manifold Studs > Page 3296 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Technical Service Bulletins > Page 3297 Exhaust Manifold: Specifications Exhaust Manifold Nuts 23-27 Nm Exhaust Manifold Studs 10-13 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Technical Service Bulletins > Page 3298 Exhaust Manifold: Testing and Inspection Special Tool 1. Place a Straightedge across the exhaust manifold flanges and check for warping with a feeler gauge. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Left Side Exhaust Manifold: Service and Repair Left Side Removal All Vehicles 1. Raise and support the vehicle. 2. On 4x4 vehicles, remove the front wheel opening molding. 3. Remove the front fender splash shield. 4. Remove the nut and the brake booster vacuum hose bracket. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Left Side > Page 3301 5. Disconnect. the EGR valve to exhaust manifold tube connections: - The EGR backpressure transducer hoses. - The EGR valve to exhaust manifold tube upper fitting. - The EGR valve to exhaust manifold tube lower fitting and remove the EGR valve to exhaust manifold tube. All Vehicles 6. Remove the nuts. 7. Remove the (A) nuts and the (B) exhaust manifold. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Left Side > Page 3302 8. Remove and discard the exhaust manifold gasket. 9. Clean and inspect the exhaust manifold. Installation All Vehicles 1. Position the exhaust manifold gasket. 2. Position the (B) exhaust manifold and loosely install the (A) nuts. 3. Tighten the nuts in the sequence shown. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Left Side > Page 3303 4. Install the three-way catalytic converter to exhaust manifold nuts. 5. Connect the EGR valve to exhaust manifold tube upper fitting. - On 4.6L engines, tighten both fittings starting at the top in two stages. Stage 1: Hand1 tighten. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Left Side > Page 3304 - Stage 2: Tighten to 35-45 Nm (26-33 ft. lbs.). - On 5.4L Engines, tighten both fittings starting at the top in two Stages. Stage 1: Hand tighten. - Stage 2: Tighten to 55-65 Nm (41-47 ft. lbs.). All Vehicles 6. Position the brake booster vacuum hose bracket and install the nut. 7. Install the front fender splash shield. 8. On 4x4 vehicles, install the front wheel opening molding. 9. Lower the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Left Side > Page 3305 Exhaust Manifold: Service and Repair Right Side Removal 1. Raise and support the vehicle. 2. On 4x4 vehicles, remove the front wheel opening molding. 3. Remove the front fender splash shield. 4. Remove the three-way catalytic converter to exhaust manifold nuts. 5. Remove the eight (A) nuts and the (B) exhaust manifold. 6. Remove and discard the exhaust manifold gasket. 7. Clean and inspect the exhaust manifold. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Left Side > Page 3306 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Page 3307 Special Tool Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information > Service and Repair Exhaust Pipe: Service and Repair For further information regarding this component, please refer to Muffler; Service and Repair. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications Heat Shield: Specifications Heat Shield Screws 13-17 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component Information > Specifications > Page 3314 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Specifications Muffler: Specifications Muffler Inlet Pipe to TWC Clamp Nuts 40-55 Nm Muffler to Catalytic Converter Pipe Clamp Nuts 40-55 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Specifications > Page 3318 Muffler: Service and Repair Removal 1. Raise and support the vehicle. 2. Remove the muffler to Three-Way Catalytic Converter (TWC) pipe clamp. 1 Remove the nuts. 2 Remove the clamp. 3. NOTE: The three tailpipe hanger insulators can be reused if they show no signs of damage. Remove the tailpipe hanger insulators and discard if damaged. 4. NOTE: It may be necessary to heat the TWC joint to ease removal. Remove the muffler and tailpipe assembly. Installation 1. Position the muffler and tailpipe assembly. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Specifications > Page 3319 2. CAUTION: Do not use oil or grease-based lubricants on insulators which deteriorates the rubber. NOTE: A soap and water solution will ease installation of the muffler hangers into the rubber tailpipe hanger insulators. Install the tailpipe hanger insulators. 3. Install the muffler to catalytic converter pipe clamp. 1 Position the clamp. 2 Install the nuts. 4. Lower the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Alternative Fuel Control Module > Component Information > Technical Service Bulletins > Bi-Fuel System - Compuvalve Replacement Alternative Fuel Control Module: Technical Service Bulletins Bi-Fuel System - Compuvalve Replacement Article No. 01-10-6 05/28/01 DRIVEABLITY - BI-FUEL - COMPUVALVE PRE-REPLACEMENT CHECK LIST - SERVICE TIPS FORD: 1996-2000 CONTOUR 1994-2001 F-150, F-250 LD 1995-2001 E-250, E-350 1999-2001 SUPER DUTY F SERIES ISSUE This article will be used as an aid in diagnosis to avoid unnecessary replacement of the compuvalve on bi-fuel vehicles after normal diagnosis has determined the compuvalve may be faulty. ACTION Complete the normal diagnostic methods and pinpoint tests. Should the conclusion be after normal diagnosis to replace the compuvalve, then follow the compuvalve Pre-Replacement Checklist (below) before replacing the compuvalve. SERVICE INFORMATION Glossary Of Terms ^ ALT - Alternate Fuel Mode ^ FAP - Fuel Absolute Pressure ^ HPS - High Pressure Solenoid ^ VCL - Vehicle Communications Link ^ AFCM - Alternate Fuel Control Module ^ WDS - Worldwide Diagnostic System ^ DTC - Diagnostic Trouble Code ^ MAP - Manifold Absolute Pressure ^ LPG - Liquid Propane Gas ^ EEC - Electronic Engine Control NOTE THE FOLLOWING IS A LIST OF KNOWN MIS-DIAGNOSIS OF THE COMPUVALVE REPLACEMENT ON BI-FUEL VEHICLES. 1. MAP line loose. 2. High FAP from vaporizer breakdown. 3. Incorrect interpretation of DTCs. 4. VCL replacement due to harness faults. 5. Misfire due to leaking 0-rings. 6. Compuvalve replaced without checking HPS circuit for correct resistance. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Alternative Fuel Control Module > Component Information > Technical Service Bulletins > Bi-Fuel System - Compuvalve Replacement > Page 3327 7. Low FAP due to lockoff fault. 8. LPG fuel filter in backward. COMPUVALVE PRE-REPLACEMENT CHECKLIST 1. Check communication ability with EEC, AFCM/compuvalve and VCL and compuvalve. Follow the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual procedures for the appropriate vehicle. 2. Check MAP line. Follow normal diagnostic methods and visual checks. 3. Check harness and connection integrity. Follow normal diagnostic methods, basic circuit checks and harness connections. 4. Check current bi-fuel EEC calibration code. Refer to WDS. 5. Check fuel gauge with fuel selector switch in ALT position for fuel level. 6. Check power to compuvalve. Power to the compuvalve is indicated by the following fuel selector switch light status: On steady = OK, On then Off or Flashing (regular and irregular) indicated fault. 7. Check that the arrow on the LPG fuel filter is pointing in the direction of fuel flow. 8. Check base vehicle. Run vehicle in gas mode (e.g., borderline secondary ignition). Follow normal diagnostic methods. 9. Check other applicable TSBs and special service messages. 10. Verify ALT fuel switch status. Refer to Section 1 of the appropriate PC/ED Workshop Manual. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 490000, 602300, 603300, 608000, 609000, 611000, 623000, 690000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3336 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3337 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3338 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures Engine Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 3344 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 3345 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3350 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3351 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3352 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 99-4-3 > Mar > 99 > PCM - Reprogramming Out of Vehicle Engine Control Module: All Technical Service Bulletins PCM - Reprogramming Out of Vehicle Article No. 99-4-3 03/08/99 REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS) - OUT-OF-VEHICLE - EEC V VEHICLES ONLY FORD: 1994-97 THUNDERBIRD 1994-99 MUSTANG 1995-99 CROWN VICTORIA 1996-97 PROBE 1996-99 CONTOUR, ESCORT, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR 1995-99 CONTINENTAL, GRAND MARQUIS, TOWN CAR 1996-98 MARK VIII 1996-99 MYSTIQUE, SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1994-97 F SUPER DUTY, F-250 HD, F-350 1995-99 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-97 AEROSTAR 1996-99 EXPLORER, F-150, F-250 LD 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to update the affected vehicles and to include an Application Chart for the affected vehicles. ISSUE The Federal Environmental Protection Agency (EPA) has mandated that all aftermarket service centers shall be able to either reprogram Powertrain Control Modules (PCMs) or obtain reasonably priced, timely PCM programming services at dealerships. Ford has released an out-of-vehicle EEC V reprogramming cable to support this requirement. Also, PCMs are reprogrammable to update calibration levels or to reprogram a common hardware type to a new calibration in order to fill a service need without ordering a new PCM. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 99-4-3 > Mar > 99 > PCM - Reprogramming Out of Vehicle > Page 3357 ACTION Refer to the Application Chart in this article to use the new 15- to 104-Pin Flash Cable to handle all necessary out-of-vehicle programming of EEC V modules in the vehicles listed. This may allow added flexibility in servicing aftermarket and fleet accounts as well as provide the ability to have modules updated to new calibrations through the Parts Department instead of ordering new parts. Currently, EEC V modules must be installed in a vehicle to reprogram a new calibration in the module. An aftermarket service center may bring a module to a dealership for a calibration update or may request an updated calibration be installed to a new service part. The EPA regulations require "reasonably priced, timely service" be provided by the dealer. The new 15- to 104-Pin Flash Cable works with the New Generation Star (NGS) Tester to provide the capability to reprogram a calibration on a PCM out of the vehicle. The 15- to 104-Pin Flash Cable connects between the NGS Tester and PCM 104-pin connector. The proper calibration must be downloaded to the Data Transfer Card through Service Bay Technical System (SBTS). Once the card is inserted into the NGS Tester and the cable is connected, follow the calibration download instructions displayed on the NGS screen. The 15- to 104-Pin Flash Cable (007-00587) can be ordered from Rotunda by calling 1-800-ROTUNDA. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-26-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 206000, 290000, 690000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures Engine Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 3363 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 3364 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 99-4-3 > Mar > 99 > PCM - Reprogramming Out of Vehicle Engine Control Module: All Technical Service Bulletins PCM - Reprogramming Out of Vehicle Article No. 99-4-3 03/08/99 REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS) - OUT-OF-VEHICLE - EEC V VEHICLES ONLY FORD: 1994-97 THUNDERBIRD 1994-99 MUSTANG 1995-99 CROWN VICTORIA 1996-97 PROBE 1996-99 CONTOUR, ESCORT, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR 1995-99 CONTINENTAL, GRAND MARQUIS, TOWN CAR 1996-98 MARK VIII 1996-99 MYSTIQUE, SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1994-97 F SUPER DUTY, F-250 HD, F-350 1995-99 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-97 AEROSTAR 1996-99 EXPLORER, F-150, F-250 LD 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to update the affected vehicles and to include an Application Chart for the affected vehicles. ISSUE The Federal Environmental Protection Agency (EPA) has mandated that all aftermarket service centers shall be able to either reprogram Powertrain Control Modules (PCMs) or obtain reasonably priced, timely PCM programming services at dealerships. Ford has released an out-of-vehicle EEC V reprogramming cable to support this requirement. Also, PCMs are reprogrammable to update calibration levels or to reprogram a common hardware type to a new calibration in order to fill a service need without ordering a new PCM. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 99-4-3 > Mar > 99 > PCM - Reprogramming Out of Vehicle > Page 3369 ACTION Refer to the Application Chart in this article to use the new 15- to 104-Pin Flash Cable to handle all necessary out-of-vehicle programming of EEC V modules in the vehicles listed. This may allow added flexibility in servicing aftermarket and fleet accounts as well as provide the ability to have modules updated to new calibrations through the Parts Department instead of ordering new parts. Currently, EEC V modules must be installed in a vehicle to reprogram a new calibration in the module. An aftermarket service center may bring a module to a dealership for a calibration update or may request an updated calibration be installed to a new service part. The EPA regulations require "reasonably priced, timely service" be provided by the dealer. The new 15- to 104-Pin Flash Cable works with the New Generation Star (NGS) Tester to provide the capability to reprogram a calibration on a PCM out of the vehicle. The 15- to 104-Pin Flash Cable connects between the NGS Tester and PCM 104-pin connector. The proper calibration must be downloaded to the Data Transfer Card through Service Bay Technical System (SBTS). Once the card is inserted into the NGS Tester and the cable is connected, follow the calibration download instructions displayed on the NGS screen. The 15- to 104-Pin Flash Cable (007-00587) can be ordered from Rotunda by calling 1-800-ROTUNDA. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-26-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 206000, 290000, 690000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3370 Engine Control Module: Specifications Powertrain Control Module (PCM) Connector Screws 4.5 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3373 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3374 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3375 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3376 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3377 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3378 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3379 Engine Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3380 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3381 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3382 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3383 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3384 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3385 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3386 Engine Control Module: Connector Views Diagram 25-9 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3387 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3388 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 3389 Engine Control Module: Description and Operation The powertrain control module needs the following inputs to calibrate the engine properly: ^ camshaft position. ^ engine rpm. ^ engine coolant temperature. ^ amount of engine detonation. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures Engine Control Module: Procedures Flash Electrically Erasable Programmable Read Only Memory is contained in an Integrated Circuit (IC) internally to the PCM. The EEPROM contains the vehicle strategy as well as any calibration information specific to the vehicle. The IC is reprogrammable and at times it may become necessary to reprogram or reflash the entire contents. This is usually due to either an after production strategy change or the Vehicle Identification (VID) area has been previously reprogrammed and has reached its limit. The VID block area can be tailored to accommodate various hardware changes made to the vehicle since production. The VID block is a section of memory within the IC which includes items such as octane adjust, fuel octane, fuel type, tire size and axle ratio. Programming a Replacement PCM A replacement PCM will display a label as shown. This indicates the need to retrieve VID data from the original PCM before removing from the vehicle. Refer to the flash VID block update procedure. After retrieving the VID data from the original PCM, install the new PCM. Select "Restore PCM config. (1)" to download the stored data. If the original PCM is nonfunctional, it becomes necessary to manually reprogram the VID block. The scan tool is used to perform this procedure and is done through the "PCM Programming" selection as described by the flash EEPROM procedure below. Follow screen instructions. Flash EEPROM Procedure When using the NGS to reprogram the entire IC contents, the NGS Flash kit will be used. The Service Bay Technical System (SBTS) is used to download the new strategy with calibration onto the NGS static RAM card (data transfer card). The card is part of the flash kit. Plug the NGS flash cable into the underdash OBD II connector. Follow the NGS screen instructions under "PCM Programming" or refer to the flash instruction manual provided in the kit. VID block information can also be viewed and changed during this procedure. Flash VID Block Procedure When using the NGS scan tool, the Ford Service Function (FSF) card is used along with the NGS flash cable. Plug the cable into the underdash OBD II connector. From the main menu, select "Service Bay Functions", "PCM-Powertrain Control Module" and then "Programmable Module Installation". The screen will now display two selections. The first is for old PCM information to be retrieved and stored within the NGS. The second is for restoring the new PCM with information which has been retrieved from the old PCM. Follow screen instructions or refer to the supplement instruction sheet included with the Ford Service Function card. Next, either a transfer of data from the old module to the new module or a manual update must be performed on the VID block. Follow screen instructions or refer to the supplement instruction sheet included with the Ford Service Function card. If the VID block has been reprogrammed previously, the scan tool will display a message. This message will indicate the need to reflash the entire IC. NOTE: If using a generic scan tool, follow the instruction manual provided by the tool manufacturer. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3392 Engine Control Module: Reset Procedure Purpose for Clearing Codes Resetting Keep Alive RAM will return PCM memory to its default setting. Adaptive learning contents such as idle and fuel trim are included. A PCM Reset is also part of a KAM Reset. After Keep Alive RAM has been reset, the vehicle may exhibit certain driveability concerns. It will be necessary to drive the vehicle to allow the PCM to relearn values for optimum driveability and performance. A Keep Alive Random Access Memory Reset is done as follows: During Key ON, Engine OFF with the scan tool, use the Reset Keep Alive Memory function. This is found in the Active Command Modes menu on the New Generation Star scan tool. If a generic scan tool is used, this function may not be supported. Refer to scan tool manufacturer's instruction manual. If an error message is received or the scan tool does not support this function, disconnecting the battery ground cable for a minimum of 5 minutes may be used as an alternative procedure. Powertrain Control Module (PCM/KAM Reset) All OBDII scan tools support the Powertrain Control Module (PCM) reset. The PCM Reset allows the scan tool to command the PCM to clear all emission-related diagnostic information. When resetting the PCM, a DTC P1000 will be stored in the PCM until all the OBD II system monitors or components have been tested to satisfy a drive cycle, without any other faults occurring. The following events occur when a PCM reset is performed: - Clears the number of Diagnostic Trouble Codes (DTCs). - Clears the DTCs. - Clears the freeze frame data. - Clears diagnostic monitoring test results. - Resets status of the OBD II system monitors. - Sets DTC P1000. NOTE: When using the New Generation Star (NGS) Scan Tool to perform a PCM reset, press the CLEAR button. This function is performed only after retrieval of continuous DTCs. New Generation Star and Generic Scan Tool Refer to the scan tool manufacturer's manual for specific instructions on how to perform PCM reset. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3393 Engine Control Module: Removal and Replacement REMOVAL 1. Remove the battery and battery tray. 2. Loosen the bolt and separate the PCM electrical connectors. 3. Remove the RH front door scuff plate. 4. Remove the RH cowl side trim panel. 5. Remove the PCM bracket clip. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 3394 6. Remove the powertrain control module. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3398 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay Main Relay (Computer/Fuel System): Testing and Inspection PCM Power Relay Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay > Page 3401 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Alternative Fuel Control Module > Component Information > Technical Service Bulletins > Bi-Fuel System - Compuvalve Replacement Alternative Fuel Control Module: Technical Service Bulletins Bi-Fuel System - Compuvalve Replacement Article No. 01-10-6 05/28/01 DRIVEABLITY - BI-FUEL - COMPUVALVE PRE-REPLACEMENT CHECK LIST - SERVICE TIPS FORD: 1996-2000 CONTOUR 1994-2001 F-150, F-250 LD 1995-2001 E-250, E-350 1999-2001 SUPER DUTY F SERIES ISSUE This article will be used as an aid in diagnosis to avoid unnecessary replacement of the compuvalve on bi-fuel vehicles after normal diagnosis has determined the compuvalve may be faulty. ACTION Complete the normal diagnostic methods and pinpoint tests. Should the conclusion be after normal diagnosis to replace the compuvalve, then follow the compuvalve Pre-Replacement Checklist (below) before replacing the compuvalve. SERVICE INFORMATION Glossary Of Terms ^ ALT - Alternate Fuel Mode ^ FAP - Fuel Absolute Pressure ^ HPS - High Pressure Solenoid ^ VCL - Vehicle Communications Link ^ AFCM - Alternate Fuel Control Module ^ WDS - Worldwide Diagnostic System ^ DTC - Diagnostic Trouble Code ^ MAP - Manifold Absolute Pressure ^ LPG - Liquid Propane Gas ^ EEC - Electronic Engine Control NOTE THE FOLLOWING IS A LIST OF KNOWN MIS-DIAGNOSIS OF THE COMPUVALVE REPLACEMENT ON BI-FUEL VEHICLES. 1. MAP line loose. 2. High FAP from vaporizer breakdown. 3. Incorrect interpretation of DTCs. 4. VCL replacement due to harness faults. 5. Misfire due to leaking 0-rings. 6. Compuvalve replaced without checking HPS circuit for correct resistance. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Alternative Fuel Control Module > Component Information > Technical Service Bulletins > Bi-Fuel System - Compuvalve Replacement > Page 3407 7. Low FAP due to lockoff fault. 8. LPG fuel filter in backward. COMPUVALVE PRE-REPLACEMENT CHECKLIST 1. Check communication ability with EEC, AFCM/compuvalve and VCL and compuvalve. Follow the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual procedures for the appropriate vehicle. 2. Check MAP line. Follow normal diagnostic methods and visual checks. 3. Check harness and connection integrity. Follow normal diagnostic methods, basic circuit checks and harness connections. 4. Check current bi-fuel EEC calibration code. Refer to WDS. 5. Check fuel gauge with fuel selector switch in ALT position for fuel level. 6. Check power to compuvalve. Power to the compuvalve is indicated by the following fuel selector switch light status: On steady = OK, On then Off or Flashing (regular and irregular) indicated fault. 7. Check that the arrow on the LPG fuel filter is pointing in the direction of fuel flow. 8. Check base vehicle. Run vehicle in gas mode (e.g., borderline secondary ignition). Follow normal diagnostic methods. 9. Check other applicable TSBs and special service messages. 10. Verify ALT fuel switch status. Refer to Section 1 of the appropriate PC/ED Workshop Manual. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 490000, 602300, 603300, 608000, 609000, 611000, 623000, 690000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3411 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3412 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3415 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3416 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3417 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3418 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3419 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3420 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3421 Fuel Pump Relay: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3422 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3423 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3424 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3425 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3426 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3427 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 3428 Fuel Pump Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 3429 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 3433 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay Main Relay (Computer/Fuel System): Testing and Inspection PCM Power Relay Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay > Page 3436 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3447 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3448 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3454 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3455 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3456 Air Flow Meter/Sensor: Specifications Mass Airflow Sensor (MAF) Plate Nuts 8-11.5 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3457 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3458 Air Flow Meter/Sensor: Service and Repair REMOVAL WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. THE SENSOR CAN BE DAMAGED BY TOUCHING. 1. Disconnect the battery ground cable. 2. Open the engine air cleaner. ^ Disconnect the Mass Air Flow (MAF) sensor connector from the wiring harness. ^ Release the air cleaner clamp. ^ Separate the inlet side of the air cleaner from the outlet side of the air cleaner. 3. Cut the tape on the wire loom of the extension harness. ^ Peel back the wire loom from the extension harness near the grommet in the air cleaner. CAUTION: Do not cut the MAF sensor wires when cutting the tape on the wire loom. 4. Remove the grommet from the outlet side of the air cleaner and slide the grommet down the extension harness. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3459 5. Remove the MAF sensor plate and mass air flow sensor from the outlet side of the engine air cleaner. 6. Disconnect the MAF sensor connector. 7. Remove the nuts and separate the MAF plate from the mass air flow sensor. INSTALLATION 1. Follow the removal procedure in reverse order. CAUTION ^ Do not tamper with the MAF sensing elements located in the airflow bypass; tampering may result in unit failure. ^ The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. NOTE ^ The MAF sensor module and body are calibrated and replaced as a unit. ^ Use the alignment notch to properly align the inlet side and the outlet side of the engine air cleaner. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3468 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3469 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3470 DISCLAIMER Service Procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3471 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3472 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3473 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3474 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3475 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3476 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3477 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3478 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3479 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3480 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3486 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3487 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3488 DISCLAIMER Service Procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3489 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3490 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3491 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3492 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3493 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3494 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3495 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3496 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3497 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3498 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3499 Camshaft Position Sensor: Specifications Camshaft Position (CMP) Sensor Bolt 8-12 Nm Camshaft Position Sensor 8-12 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3500 Camshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Camshaft Position (CMP) sensor 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the camshaft position sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams > Page 3504 Clutch Switch: Service and Repair REMOVAL 1. Disconnect electrical connector from clutch pedal position switch. 2. Release the clutch pedal position switch from the orientation clip. 3. Remove the plastic retainer. 1 Push the lock tabs together. 2 Slide the plastic retainer off the clutch pedal position switch. 4. Remove the clutch pedal position switch. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor (ECT) 16-24 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications Engine Temperature Sensor: Specifications Cylinder Head Temperature (CHT) Sensor 6.9-13.5 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications > Page 3511 Engine Temperature Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Remove the Cylinder Head Temperature (CHT) sensor. 1 Disconnect the connector. 2 Remove the CHT sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service and Repair Fuel Tank Pressure Sensor: Service and Repair REMOVAL 1. Remove the fuel tank. 2. Disconnect the electrical connector. CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Push down while rotating the sensor counterclockwise to disengage it from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. 3. Press down and rotate the fuel tank pressure sensor counterclockwise and remove it from the fuel tank. INSTALLATION 1. To install, reverse the removal procedure. 2. Leak test the system. 3. Carry out the Evaporative Emission Running Loss Monitor Repair Verification Drive Cycle Test. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair Intake Air Temperature Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the connector. 3. Remove the intake air temperature sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Linear Knock Sensor 16.2-23.8 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 3521 Knock Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Remove the knock sensor. 1 Disconnect the connector. 2 Remove the knock sensor. NOTE: This engine is equipped with a unique linear knock sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics Oxygen Sensor: Technical Service Bulletins Engine Controls - Bi-Fuel O2 Sensor Diagnostics Article No. 03-6-6 03/31/03 DRIVEABILITY - BI-FUEL - OXYGEN SENSOR DIAGNOSTICS - HIGH OXYGEN SENSOR VOLTAGE READING FORD: 1998-2000 CONTOUR 1998-1999 E SERIES 1998-2003 F-150 1999 F-250 ISSUE Some Bi-Fuel vehicles may exhibit DTC's for high Oxygen Sensor voltage (P0132 and P0152). Current diagnostics may result in premature replacement of the Compuvalve. ACTION If an Oxygen Sensor code is set, the current diagnostics direct the Compuvalve to be replaced it no faults are detected when Pinpoint Test H is conducted. The modified repair action outlined below gives additional test procedures if nothing is detected from Pinpoint Test H. SERVICE PROCEDURE 1. Prior to clearing any codes, to aid in diagnostics of intermittent failures, access and record the freeze frame data using the NGS Tester. 2. At step H4 of the pinpoint test, it Oxygen Sensor PIDS (H02S11 and H02521) are within specification (see table in Section H of PC/ED Manual), clear codes and road test the vehicle in alternative fuel using the freeze frame data (from above) to duplicate conditions that triggered the code. During the road test, monitor Oxygen Sensor PIDs for both banks in both the PCM and the AFCM. NOTE A SECOND TECHNICIAN SHOULD MONITOR THE PIDS WHILE THE OTHER DRIVES. IF THE CODE/CONCERN CANNOT BE DUPLICATED, REFER TO PINPOINT TEST Z OF THE BASE VEHICLE PC/ED. 3. If the concern is duplicated, and if voltage is outside of specifications in both the AFCM and the PCM, the fault is in the Heated Exhaust Gas Oxygen (HEGO) sensor circuit. Refer to base vehicle diagnostics. 4. If the voltage is outside of specifications in the AFCM only, replace the Compuvalve. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 490000, 698298 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3526 Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3527 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3528 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3529 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3530 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3531 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3532 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3533 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3534 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3535 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3536 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3537 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3538 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3539 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3540 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 3541 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 3542 Oxygen Sensor: Specifications Heated Oxygen Sensor (HO2S) 36-46 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > OBD-II Heated Oxygen Sensor Numbering Convention Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > OBD-II Heated Oxygen Sensor Numbering Convention > Page 3545 Oxygen Sensor: Locations Component Location 4.2L/4.6L 5.4L/6.8L Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3548 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3549 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3550 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3551 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3552 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3553 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3554 Oxygen Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3555 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3556 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3557 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3558 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3559 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3560 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3561 Oxygen Sensor: Connector Views Oxygen Sensor Vehicle Harness Connector PCM Connector Pin Numbers Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) - Front Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) - Front Oxygen Sensor Wrench Special Tool(s) REMOVAL WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. NEVER ATTEMPT TO SERVICE ANY PART OF THE SYSTEM UNTIL IT HAS COOLED. BE ESPECIALLY CAREFUL WHEN WORKING AROUND THE THREE WAY CATALYTIC CONVERTER. THE TEMPERATURE OF THE THREE WAY CATALYTIC CONVERTER RISES TO A HIGH LEVEL AFTER ONLY A FEW MINUTES OF ENGINE OPERATION. 1. Turn the ignition switch OFF. 2. Disconnect the connector. 3. Raise and support the vehicle. 4. Use Oxygen Sensor Wrench to remove the heated oxygen sensor. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) - Front > Page 3564 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) - Front > Page 3565 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) - Rear Oxygen Sensor Wrench Special Tool(s) REMOVAL WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. NEVER ATTEMPT TO SERVICE ANY PART OF THE SYSTEM UNTIL IT HAS COOLED. BE ESPECIALLY CAREFUL WHEN WORKING AROUND THE THREE WAY CATALYTIC CONVERTER. THE TEMPERATURE OF THE THREE WAY CATALYTIC CONVERTER RISES TO A HIGH LEVEL AFTER ONLY A FEW MINUTES OF ENGINE OPERATION. 1. Turn the ignition switch OFF. 2. Raise and support the vehicle. 3. Remove the heated oxygen sensor. 1 Disconnect the connector. 2 Use the Oxygen Sensor Wrench to remove the heated oxygen sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications Pressure Feedback Exhaust Sensor: Specifications Differential Pressure Feedback EGR Sensor Nuts 8-12 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3569 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Remove the differential pressure feedback EGR sensor. 1 Remove the differential pressure feedback EGR sensor tubes. 2 Disconnect the differential pressure feedback EGR sensor electrical connector. 3 Remove the two nuts. 4 Remove the differential pressure feedback EGR sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position (TP) Sensor Screws 2.8-3.4 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 3573 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the shield. 3. Remove the throttle position sensor. 1 Disconnect the connector. 2 Remove the bolts. 3 Remove the throttle position sensor. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 3574 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > 4R70W Transmission Position Switch/Sensor: Specifications Digital Transmission Range Sensor Bolts 7-10 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > 4R70W > Page 3579 Transmission Position Switch/Sensor: Specifications Digital Transmission TR Sensor 8-10 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 3580 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W Transmission Position Switch/Sensor: Service and Repair 4R70W Special Tools 1. Raise and support vehicle. 2. Disconnect the manual lever shift control cable. 3. Disconnect the digital TR electrical connector. 4. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. The old nut will not retain torque specification. Remove the manual control lever. 1 Remove the nut. 2 Remove the lever. 5. Loosen the digital TR sensor bolts. 6. NOTE: Manual shift lever must be in the neutral position. Use digital transmission range TR Sensor Alignment Tool, to align the digital TR sensor slots. The tool is designed to fit snug. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W > Page 3583 7. Tighten the bolts. 8. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual lever shaft outer nut. 9. With the manual lever in overdrive connect the shift lever control cable. 10. Install the digital TR sensor electrical connector. 11. Lower the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W > Page 3584 Transmission Position Switch/Sensor: Service and Repair 4R100 Special Tools Removal 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Disconnect the connector. 4. Disconnect the shift cable at the manual control lever. 5. Remove the digital Transmission Range (TR) sensor. 1 Remove the bolts. 2 Remove the digital Transmission Range (TR) sensor. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W > Page 3585 1. Install the digital Transmission Range (TR) sensor. 1 Install digital Transmission Range (TR) sensor. 2 Loosely install the bolts. 2. NOTE: Make sure that the manual control lever is in the neutral position. Install the Digital Transmission Range (TR) Sensor Alignment Tool. The tool is designed to fit snug. 3. Tighten the bolts. 4. Reconnect the shift cable at the manual control lever. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W > Page 3586 5. Reconnect the connector. 6. Lower the vehicle. 7. Reconnect the battery ground cable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Tools and Equipment > 4R70W Special Tool Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Tools and Equipment > 4R70W > Page 3589 Special Tool Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications Vehicle Speed Sensor Bolt 11-13 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3595 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3596 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3597 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3598 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3599 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3600 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3601 Vehicle Speed Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3602 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3603 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3604 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3605 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3606 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3607 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications Pressure Feedback Exhaust Sensor: Specifications Differential Pressure Feedback EGR Sensor Nuts 8-12 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 3612 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Remove the differential pressure feedback EGR sensor. 1 Remove the differential pressure feedback EGR sensor tubes. 2 Disconnect the differential pressure feedback EGR sensor electrical connector. 3 Remove the two nuts. 4 Remove the differential pressure feedback EGR sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3622 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3623 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3629 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3630 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator Radiator: All Technical Service Bulletins A/T Cooler - Fluid Leaks at Radiator Article No. 00-9-1 DATE 5/1/00 TITLE LEAK - TRANSMISSION FLUID LEAKS AT RADIATOR - VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSION AND TRANSMISSION OIL COOLER IN RADIATOR END TANK FORD: 1997-2000 MUSTANG, EXPEDITION, EXPLORER, F-150, F-250 LD 1998-2000 RANGER 1999-2000 SUPER DUTY F SERIES LINCOLN: 1998-2000 NAVIGATOR MERCURY: 1998-2000 MOUNTAINEER This TSB is being republished in its entirety to update the vehicles affected and to update the Service Procedure. ISSUE Transmission fluid may leak between the radiator transmission oil cooler and the transmission oil cooler fitting (NOT the cooler line into the fitting), which may result in a residue of transmission fluid on the radiator tank around the transmission oil cooler fitting. This may be caused by insufficient thread sealer on the transmission oil cooler fitting. NOTE: THIS TSB DOES NOT APPLY TO TRANSMISSION FLUID LEAKAGE AT THE TRANSMISSION LINE TO TRANSMISSION OIL COOLER FITTING. ACTION Install O-ring W705181-S onto the transmission oil cooler fitting. The O-ring is designed to seal the leak and reduce the possibility of transmission fluid leakage. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify that transmission fluid is leaking between the transmission oil cooler and the transmission oil cooler fitting (NOT the transmission cooler line fitting into the transmission oil cooler fitting). Refer to Figure 1. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 3636 2. Remove the radiator from the vehicle following Workshop Manual procedure. Place the radiator on a flat surface so that the transmission oil cooler fittings are facing upward. Refer to Figure 2. 3. Clean the area around the transmission oil cooler fitting. This will insure that contaminants do not enter the transmission oil cooler when the transmission oil cooler fittings are removed. CAUTION: OIL-BASED SOLVENTS AND CLEANERS SHOULD NOT BE USED WHEN CLEANING THE RADIATOR. OIL-BASED SOLVENTS AND CLEANERS CAN DAMAGE THE RADIATOR END TANK SEALS AND CAUSE LEAKS. 4. Remove the upper transmission oil cooler fitting. NOTE: REMOVE ONLY ONE (1) TRANSMISSION OIL COOLER FITTING AT A TIME, OTHERWISE THE COOLER MAY DROP INTO THE RADIATOR. 5. Once the fitting is removed from the transmission oil cooler, verify that there is a gasket between the transmission oil cooler and the inside of the radiator tank. If there is no gasket, replace the radiator. If the gasket is in place, continue to Step 6. 6. Inspect the transmission oil cooler fitting threads for damage. If the threads are damaged, replace the radiator. If the threads show no sign of damage, continue to Step 7. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 3637 7. Install O-ring W705181-S on the transmission oil cooler fitting. Refer to Figures 2 and 3. CAUTION: THREAD SEALANT OR TAPE SHOULD NEVER BE USED ON THE THREADS OF THE TRANSMISSION OIL COOLER FITTING. THE USE OF SUCH MATERIALS WILL CREATE A LEAK PATH. 8. Making sure that the gasket between the transmission oil cooler and the inside of the radiator tank is still in place, reinstall the transmission oil cooler fitting. The fitting should be torqued to 38-45 N.m (28-33 lb-ft). NOTE:: DO NOT USE AIR TOOLS TO TORQUE THE TRANSMISSION OIL COOLER FITTING. USE A HAND-OPERATED TORQUE WRENCH ONLY. 9. Repeat Steps 2-8 for the other transmission oil cooler fitting. This fitting should also have the O-ring replaced even if it is not leaking. 10. Make sure that no radiator coolant has entered the transmission oil cooler. Reinstall the radiator in the vehicle following Workshop Manual procedure. 11. Verify that both the transmission and the engine cooling system have the proper fluid levels outlined in the Workshop Manual. PARTS INFORMATION LABOR OPERATION APPLICATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 3638 OTHER APPLICABLE ARTICLES: NONE SUPERCEDES: 99-4-6 WARRANTY STATUS OPERATION DESCRIPTION DEALER CODING OASIS CODES: 402000, 510000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 3644 2. Remove the radiator from the vehicle following Workshop Manual procedure. Place the radiator on a flat surface so that the transmission oil cooler fittings are facing upward. Refer to Figure 2. 3. Clean the area around the transmission oil cooler fitting. This will insure that contaminants do not enter the transmission oil cooler when the transmission oil cooler fittings are removed. CAUTION: OIL-BASED SOLVENTS AND CLEANERS SHOULD NOT BE USED WHEN CLEANING THE RADIATOR. OIL-BASED SOLVENTS AND CLEANERS CAN DAMAGE THE RADIATOR END TANK SEALS AND CAUSE LEAKS. 4. Remove the upper transmission oil cooler fitting. NOTE: REMOVE ONLY ONE (1) TRANSMISSION OIL COOLER FITTING AT A TIME, OTHERWISE THE COOLER MAY DROP INTO THE RADIATOR. 5. Once the fitting is removed from the transmission oil cooler, verify that there is a gasket between the transmission oil cooler and the inside of the radiator tank. If there is no gasket, replace the radiator. If the gasket is in place, continue to Step 6. 6. Inspect the transmission oil cooler fitting threads for damage. If the threads are damaged, replace the radiator. If the threads show no sign of damage, continue to Step 7. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 3645 7. Install O-ring W705181-S on the transmission oil cooler fitting. Refer to Figures 2 and 3. CAUTION: THREAD SEALANT OR TAPE SHOULD NEVER BE USED ON THE THREADS OF THE TRANSMISSION OIL COOLER FITTING. THE USE OF SUCH MATERIALS WILL CREATE A LEAK PATH. 8. Making sure that the gasket between the transmission oil cooler and the inside of the radiator tank is still in place, reinstall the transmission oil cooler fitting. The fitting should be torqued to 38-45 N.m (28-33 lb-ft). NOTE:: DO NOT USE AIR TOOLS TO TORQUE THE TRANSMISSION OIL COOLER FITTING. USE A HAND-OPERATED TORQUE WRENCH ONLY. 9. Repeat Steps 2-8 for the other transmission oil cooler fitting. This fitting should also have the O-ring replaced even if it is not leaking. 10. Make sure that no radiator coolant has entered the transmission oil cooler. Reinstall the radiator in the vehicle following Workshop Manual procedure. 11. Verify that both the transmission and the engine cooling system have the proper fluid levels outlined in the Workshop Manual. PARTS INFORMATION LABOR OPERATION APPLICATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Flow Meter/Sensor: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 3646 OTHER APPLICABLE ARTICLES: NONE SUPERCEDES: 99-4-6 WARRANTY STATUS OPERATION DESCRIPTION DEALER CODING OASIS CODES: 402000, 510000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3647 Air Flow Meter/Sensor: Specifications Mass Airflow Sensor (MAF) Plate Nuts 8-11.5 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3648 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3649 Air Flow Meter/Sensor: Service and Repair REMOVAL WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. THE SENSOR CAN BE DAMAGED BY TOUCHING. 1. Disconnect the battery ground cable. 2. Open the engine air cleaner. ^ Disconnect the Mass Air Flow (MAF) sensor connector from the wiring harness. ^ Release the air cleaner clamp. ^ Separate the inlet side of the air cleaner from the outlet side of the air cleaner. 3. Cut the tape on the wire loom of the extension harness. ^ Peel back the wire loom from the extension harness near the grommet in the air cleaner. CAUTION: Do not cut the MAF sensor wires when cutting the tape on the wire loom. 4. Remove the grommet from the outlet side of the air cleaner and slide the grommet down the extension harness. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3650 5. Remove the MAF sensor plate and mass air flow sensor from the outlet side of the engine air cleaner. 6. Disconnect the MAF sensor connector. 7. Remove the nuts and separate the MAF plate from the mass air flow sensor. INSTALLATION 1. Follow the removal procedure in reverse order. CAUTION ^ Do not tamper with the MAF sensing elements located in the airflow bypass; tampering may result in unit failure. ^ The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. NOTE ^ The MAF sensor module and body are calibrated and replaced as a unit. ^ Use the alignment notch to properly align the inlet side and the outlet side of the engine air cleaner. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Specifications Inertia Fuel Shutoff Switch: Specifications Intertia Fuel Shutoff Switch Bolts .............................................................................................................................................. 1.6-2.2 N.m (14.2-19 Lb-In) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position (TP) Sensor Screws 2.8-3.4 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3657 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the shield. 3. Remove the throttle position sensor. 1 Disconnect the connector. 2 Remove the bolts. 3 Remove the throttle position sensor. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 3658 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3668 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3669 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3670 DISCLAIMER Service Procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3671 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3672 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3673 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3674 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3675 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3676 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3677 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3678 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3679 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3680 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3686 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3687 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3688 DISCLAIMER Service Procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3689 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3690 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3691 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3692 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3693 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3694 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3695 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3696 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3697 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3698 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3699 Camshaft Position Sensor: Specifications Camshaft Position (CMP) Sensor Bolt 8-12 Nm Camshaft Position Sensor 8-12 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3700 Camshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Camshaft Position (CMP) sensor 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the camshaft position sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3709 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3710 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3711 DISCLAIMER Service Procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3712 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3713 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3714 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3715 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3716 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3717 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3718 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3719 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3720 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3721 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3727 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 3728 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > NHTSA98V192000 > Aug > 98 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > NHTSA98V192000 > Aug > 98 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3738 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > NHTSA98V192000 > Aug > 98 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3739 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > NHTSA98V192000 > Aug > 98 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3740 DISCLAIMER Service Procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > NHTSA98V192000 > Aug > 98 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3741 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > NHTSA98V192000 > Aug > 98 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3742 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > NHTSA98V192000 > Aug > 98 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3743 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > NHTSA98V192000 > Aug > 98 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3744 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > NHTSA98V192000 > Aug > 98 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3745 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > NHTSA98V192000 > Aug > 98 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3746 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > NHTSA98V192000 > Aug > 98 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3747 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > NHTSA98V192000 > Aug > 98 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3748 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > NHTSA98V192000 > Aug > 98 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3749 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > NHTSA98V192000 > Aug > 98 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3750 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Hose: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Hose: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3756 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Hose: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3757 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Hose: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3758 DISCLAIMER Service Procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Hose: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3759 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Hose: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3760 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Hose: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3761 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Hose: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3762 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Hose: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3763 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Hose: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3764 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Hose: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3765 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Hose: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3766 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Hose: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3767 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Heater Hose: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3768 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 3774 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 3775 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 3776 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 3777 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 3778 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 3779 Ignition Switch Lock Cylinder: Specifications TORQUE SPECIFICATIONS Lock Cylinder Housing Screws .................................................................................................................................................. 18-26 Nm (14-19 ft. lbs.) Key Release Button Bolt ............................................................................................................................................................ 4-6 Nm (36-53 inch lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Lock Cylinder Ignition Switch Lock Cylinder: Service and Repair Functional Lock Cylinder Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1. Insert the ignition key and turn to the RUN position. 2. Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock cylinder. Installation 1. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Lock Cylinder > Page 3782 Ignition Switch Lock Cylinder: Service and Repair Key Release Button Removal 1. Remove the ignition switch lock cylinder. 1. Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2. Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. 2. Twist the tilt wheel handle and shank and remove. 3. Release the four clips and remove the steering column opening cover. 4. Remove the upper and lower steering column shrouds. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Lock Cylinder > Page 3783 1. Remove the three screws. 2. Remove the lower steering column shroud. 3. Remove the upper steering column shroud. 5. Remove the key release button. 1. Remove the bolt. 2. Remove the spring. 3. Remove the key release button. Installation 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Lock Cylinder > Page 3784 Ignition Switch Lock Cylinder: Service and Repair Non-Functional Lock Cylinder Removal WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Lock Cylinder > Page 3785 4. Remove the ignition switch lock cylinder. ^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. ^ Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. ^ Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. 6. Remove the bearing and the gear. ^ Thoroughly clean all drill shavings from the steering column and inspect it for damage. Installation The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Lock Cylinder > Page 3786 1. NOTE: Use a new ignition switch lock cylinder. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Linear Knock Sensor 16.2-23.8 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 3790 Knock Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Remove the knock sensor. 1 Disconnect the connector. 2 Remove the knock sensor. NOTE: This engine is equipped with a unique linear knock sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications Fuel Pressure Test Port: Specifications Fuel pressure relief valve 8 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 3796 Fuel Pressure Test Port: Service and Repair REMOVAL WARNING ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Release fuel pressure. 2. Remove the pressure relief valve. INSTALLATION 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > With 4R70W Idle Speed: Specifications With 4R70W Hot Idle ................................................................................................................................................ .................................................................. 720 RPM Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications > With 4R70W > Page 3801 Idle Speed: Specifications With 4R100 Hot Idle ................................................................................................................................................ ......................................................... 760 - 830 RPM Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair REMOVAL 1. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the shield. 2. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. 3. Disconnect the (A) Positive Crankcase Ventilation (PCV) hose and the (B) Idle Air Control (IAC) valve inlet tube. 4. Loosen the clamps and remove the air cleaner outlet tube and resonator. INSTALLATION 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 3806 CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. NOTE: The inlet air cleaner has an alignment tab which fits into a slot on the outlet air cleaner. Make sure the tabs are aligned correctly. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair REMOVAL 1. Open the (A) air cleaner clamp and set the (B) outlet Air Cleaner (ACL) aside. 2. Remove the (A) Air Cleaner (ACL) element from the (B) open end of inlet. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. NOTE: The inlet air cleaner has an alignment tab which fits into a slot on the outlet air cleaner. Make sure tabs are aligned correctly. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Gauge Special Tool(s) WARNING - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the Schrader valve cap and install the Fuel Pressure Gauge. 2. Open the manual valve slowly on the Fuel Pressure Gauge and relieve the fuel pressure. - This will drain some fuel out of the system. Place the fuel in a suitable container. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications The RH (Passenger's) side ................................................................................................................. ................................................ Cylinders 1, 2, 3, and 4 The LH (Driver's side) .......................................................................................................................... ............................................. Cylinders 5, 6, 7 and 8 Firing Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap Spark Plug: Specifications Spark Plug Gap 1.32-1.42 mm Spark Plugs 15 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Gap > Page 3825 Spark Plug: Specifications Spark Plug Gap 1.32-1.42 mm Spark Plugs 15 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3826 Spark Plug: Application and ID Original Spark Plug .............................................................................................................................. ............................................................... AWSF12E Replacement Spark Plug ................................... ................................................................................................................................................... AWSF12E Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3827 Spark Plug: Description and Operation The spark plug: ^ changes high-voltage pulses to sparks at gap which ignites fuel and air mixture. ^ originally equipped on the vehicle; has a platinum-enhanced active electrode for long life. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3828 Spark Plug: Service and Repair REMOVAL 1. Remove the Coil On Plug (COP). Remove the screw and the coil for each plug. NOTE: Remove any foreign debris from the spark plug wells with compressed air. 2. Remove the RH spark plugs. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3829 3. Remove the LH spark plugs. 4. Inspect the spark plugs for: - Deposits bridging spark plug gap (A). - Wet black deposits (oil fouling) (B). - Dry black deposits (carbon fouling) (C). - Overheating (D). - Deposits fused on spark plug (E). - Pre-ignition damage (F). - Normal spark plug (G). 5. Adjust the spark plug as required. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3830 INSTALLATION 1. Install the LH spark plugs. 2. Install the RH spark plugs. 3. Install the COPs. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications Compression Pressure Limit Chart Compression Pressure Limit Chart The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 3834 Compression Check: Testing and Inspection 1. Make sure the oil in the crankcase is of the correct viscosity and at the proper level and that the battery is properly charged. Operate the vehicle until the engine is at normal operating temperature. Turn the ignition switch to the OFF position, then remove all the spark plugs. 2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the Compression Tester in the No. 1 cylinder. 4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, and using the auxiliary starter switch, crank the engine a minimum of five compression strokes and record the highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat the test on each cylinder, cranking the engine approximately the same number of compression strokes. Compression Pressure Limit Chart Compression Pressure Limit Chart The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest reading. If one or more cylinders reads low, squirt approximately one tablespoon of Super Premium SAE 5W30 Motor Oil, X0-5W30-QSP meeting Ford specification WSS-M2C153-G on top of the pistons in the low-reading cylinders. Repeat the compression pressure check on these cylinders. - If compression improves considerably, piston rings are faulty. - If compression does not improve, valves are sticking or seating improperly. - If two adjacent cylinders indicate low compression pressures and squirting oil on each piston does not increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications The manufacturer does not indicate whether this vehicle has adjustable or non-adjustable valves. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3847 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3848 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3854 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 3855 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3856 Air Flow Meter/Sensor: Specifications Mass Airflow Sensor (MAF) Plate Nuts 8-11.5 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3857 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3858 Air Flow Meter/Sensor: Service and Repair REMOVAL WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. THE SENSOR CAN BE DAMAGED BY TOUCHING. 1. Disconnect the battery ground cable. 2. Open the engine air cleaner. ^ Disconnect the Mass Air Flow (MAF) sensor connector from the wiring harness. ^ Release the air cleaner clamp. ^ Separate the inlet side of the air cleaner from the outlet side of the air cleaner. 3. Cut the tape on the wire loom of the extension harness. ^ Peel back the wire loom from the extension harness near the grommet in the air cleaner. CAUTION: Do not cut the MAF sensor wires when cutting the tape on the wire loom. 4. Remove the grommet from the outlet side of the air cleaner and slide the grommet down the extension harness. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 3859 5. Remove the MAF sensor plate and mass air flow sensor from the outlet side of the engine air cleaner. 6. Disconnect the MAF sensor connector. 7. Remove the nuts and separate the MAF plate from the mass air flow sensor. INSTALLATION 1. Follow the removal procedure in reverse order. CAUTION ^ Do not tamper with the MAF sensing elements located in the airflow bypass; tampering may result in unit failure. ^ The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. NOTE ^ The MAF sensor module and body are calibrated and replaced as a unit. ^ Use the alignment notch to properly align the inlet side and the outlet side of the engine air cleaner. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair Intake Air Temperature Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the connector. 3. Remove the intake air temperature sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Alternative Fuel Control Module > Component Information > Technical Service Bulletins > Bi-Fuel System - Compuvalve Replacement Alternative Fuel Control Module: Technical Service Bulletins Bi-Fuel System - Compuvalve Replacement Article No. 01-10-6 05/28/01 DRIVEABLITY - BI-FUEL - COMPUVALVE PRE-REPLACEMENT CHECK LIST - SERVICE TIPS FORD: 1996-2000 CONTOUR 1994-2001 F-150, F-250 LD 1995-2001 E-250, E-350 1999-2001 SUPER DUTY F SERIES ISSUE This article will be used as an aid in diagnosis to avoid unnecessary replacement of the compuvalve on bi-fuel vehicles after normal diagnosis has determined the compuvalve may be faulty. ACTION Complete the normal diagnostic methods and pinpoint tests. Should the conclusion be after normal diagnosis to replace the compuvalve, then follow the compuvalve Pre-Replacement Checklist (below) before replacing the compuvalve. SERVICE INFORMATION Glossary Of Terms ^ ALT - Alternate Fuel Mode ^ FAP - Fuel Absolute Pressure ^ HPS - High Pressure Solenoid ^ VCL - Vehicle Communications Link ^ AFCM - Alternate Fuel Control Module ^ WDS - Worldwide Diagnostic System ^ DTC - Diagnostic Trouble Code ^ MAP - Manifold Absolute Pressure ^ LPG - Liquid Propane Gas ^ EEC - Electronic Engine Control NOTE THE FOLLOWING IS A LIST OF KNOWN MIS-DIAGNOSIS OF THE COMPUVALVE REPLACEMENT ON BI-FUEL VEHICLES. 1. MAP line loose. 2. High FAP from vaporizer breakdown. 3. Incorrect interpretation of DTCs. 4. VCL replacement due to harness faults. 5. Misfire due to leaking 0-rings. 6. Compuvalve replaced without checking HPS circuit for correct resistance. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Alternative Fuel Control Module > Component Information > Technical Service Bulletins > Bi-Fuel System - Compuvalve Replacement > Page 3867 7. Low FAP due to lockoff fault. 8. LPG fuel filter in backward. COMPUVALVE PRE-REPLACEMENT CHECKLIST 1. Check communication ability with EEC, AFCM/compuvalve and VCL and compuvalve. Follow the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual procedures for the appropriate vehicle. 2. Check MAP line. Follow normal diagnostic methods and visual checks. 3. Check harness and connection integrity. Follow normal diagnostic methods, basic circuit checks and harness connections. 4. Check current bi-fuel EEC calibration code. Refer to WDS. 5. Check fuel gauge with fuel selector switch in ALT position for fuel level. 6. Check power to compuvalve. Power to the compuvalve is indicated by the following fuel selector switch light status: On steady = OK, On then Off or Flashing (regular and irregular) indicated fault. 7. Check that the arrow on the LPG fuel filter is pointing in the direction of fuel flow. 8. Check base vehicle. Run vehicle in gas mode (e.g., borderline secondary ignition). Follow normal diagnostic methods. 9. Check other applicable TSBs and special service messages. 10. Verify ALT fuel switch status. Refer to Section 1 of the appropriate PC/ED Workshop Manual. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 490000, 602300, 603300, 608000, 609000, 611000, 623000, 690000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 02-10-8 > May > 02 > Fuel System - Whistling Noise Auxiliary Air Valve (Idle Speed): Customer Interest Fuel System - Whistling Noise Article No. 02-10-8 05/27/02 ^ DRIVEABILITY - 5.4L 2V - IDLE-AIR BYPASS FLOW INDUCED WHISTLE ^ ENGINE - 5.4L 2V - IDLE-AIR BYPASS FLOW INDUCED WHISTLE ^ NOISE - IDLE-AIR BYPASS FLOW INDUCED WHISTLE - VEHICLES EQUIPPED WITH 5.4L 2V ENGINE ONLY FORD: 1999-2002 E SERIES, EXPEDITION, F-150, SUPER DUTY F SERIES ISSUE Some vehicles equipped with the 5.4L 2V engine may exhibit a "whistling" noise from the formed nylon tube in the idle-air bypass flow circuit. This may be caused by air flow passing through the sharp bend radius of the original tube assembly. ACTION Remove and replace formed nylon tube with the Nipple And Hose Assembly 2L1Z-9W548-AA. This action will correct the sharp bend in the tube. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the formed tube as shown (Figure 1). 2. Replace with Nipple And Hose Assembly with part 2L1Z-9W548-AA. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 02-10-8 > May > 02 > Fuel System - Whistling Noise > Page 3876 3. Connect nipple to the air-inlet zip tube and the free end connects to resonator as shown (Figure 2). 4. Ensure that there are no kinks in the rubber hose which could restrict air flow. LABOR OPERATION CLAIMING CHART PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9H308 V3 OASIS CODES: 497000, 702000, 702100 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 02-10-8 > May > 02 > Fuel System - Whistling Noise Auxiliary Air Valve (Idle Speed): All Technical Service Bulletins Fuel System - Whistling Noise Article No. 02-10-8 05/27/02 ^ DRIVEABILITY - 5.4L 2V - IDLE-AIR BYPASS FLOW INDUCED WHISTLE ^ ENGINE - 5.4L 2V - IDLE-AIR BYPASS FLOW INDUCED WHISTLE ^ NOISE - IDLE-AIR BYPASS FLOW INDUCED WHISTLE - VEHICLES EQUIPPED WITH 5.4L 2V ENGINE ONLY FORD: 1999-2002 E SERIES, EXPEDITION, F-150, SUPER DUTY F SERIES ISSUE Some vehicles equipped with the 5.4L 2V engine may exhibit a "whistling" noise from the formed nylon tube in the idle-air bypass flow circuit. This may be caused by air flow passing through the sharp bend radius of the original tube assembly. ACTION Remove and replace formed nylon tube with the Nipple And Hose Assembly 2L1Z-9W548-AA. This action will correct the sharp bend in the tube. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the formed tube as shown (Figure 1). 2. Replace with Nipple And Hose Assembly with part 2L1Z-9W548-AA. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): > 02-10-8 > May > 02 > Fuel System - Whistling Noise > Page 3882 3. Connect nipple to the air-inlet zip tube and the free end connects to resonator as shown (Figure 2). 4. Ensure that there are no kinks in the rubber hose which could restrict air flow. LABOR OPERATION CLAIMING CHART PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9H308 V3 OASIS CODES: 497000, 702000, 702100 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component Information > Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3894 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3895 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3896 DISCLAIMER Service Procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3897 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3898 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3899 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3900 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3901 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3902 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3903 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3904 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3905 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3906 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3912 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3913 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3914 DISCLAIMER Service Procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3915 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3916 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3917 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3918 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3919 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3920 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3921 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3922 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3923 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 3924 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3925 Camshaft Position Sensor: Specifications Camshaft Position (CMP) Sensor Bolt 8-12 Nm Camshaft Position Sensor 8-12 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 3926 Camshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Camshaft Position (CMP) sensor 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the camshaft position sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams > Page 3930 Clutch Switch: Service and Repair REMOVAL 1. Disconnect electrical connector from clutch pedal position switch. 2. Release the clutch pedal position switch from the orientation clip. 3. Remove the plastic retainer. 1 Push the lock tabs together. 2 Slide the plastic retainer off the clutch pedal position switch. 4. Remove the clutch pedal position switch. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor (ECT) 16-24 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions Data Link Connector: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3938 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3939 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3940 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3941 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3942 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3943 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3944 Data Link Connector: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3945 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3946 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3947 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3948 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3949 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3950 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 3951 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3960 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3961 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3962 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures Engine Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 3968 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 3969 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3974 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3975 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 3976 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 99-4-3 > Mar > 99 > PCM - Reprogramming Out of Vehicle Engine Control Module: All Technical Service Bulletins PCM - Reprogramming Out of Vehicle Article No. 99-4-3 03/08/99 REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS) - OUT-OF-VEHICLE - EEC V VEHICLES ONLY FORD: 1994-97 THUNDERBIRD 1994-99 MUSTANG 1995-99 CROWN VICTORIA 1996-97 PROBE 1996-99 CONTOUR, ESCORT, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR 1995-99 CONTINENTAL, GRAND MARQUIS, TOWN CAR 1996-98 MARK VIII 1996-99 MYSTIQUE, SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1994-97 F SUPER DUTY, F-250 HD, F-350 1995-99 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-97 AEROSTAR 1996-99 EXPLORER, F-150, F-250 LD 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to update the affected vehicles and to include an Application Chart for the affected vehicles. ISSUE The Federal Environmental Protection Agency (EPA) has mandated that all aftermarket service centers shall be able to either reprogram Powertrain Control Modules (PCMs) or obtain reasonably priced, timely PCM programming services at dealerships. Ford has released an out-of-vehicle EEC V reprogramming cable to support this requirement. Also, PCMs are reprogrammable to update calibration levels or to reprogram a common hardware type to a new calibration in order to fill a service need without ordering a new PCM. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 99-4-3 > Mar > 99 > PCM - Reprogramming Out of Vehicle > Page 3981 ACTION Refer to the Application Chart in this article to use the new 15- to 104-Pin Flash Cable to handle all necessary out-of-vehicle programming of EEC V modules in the vehicles listed. This may allow added flexibility in servicing aftermarket and fleet accounts as well as provide the ability to have modules updated to new calibrations through the Parts Department instead of ordering new parts. Currently, EEC V modules must be installed in a vehicle to reprogram a new calibration in the module. An aftermarket service center may bring a module to a dealership for a calibration update or may request an updated calibration be installed to a new service part. The EPA regulations require "reasonably priced, timely service" be provided by the dealer. The new 15- to 104-Pin Flash Cable works with the New Generation Star (NGS) Tester to provide the capability to reprogram a calibration on a PCM out of the vehicle. The 15- to 104-Pin Flash Cable connects between the NGS Tester and PCM 104-pin connector. The proper calibration must be downloaded to the Data Transfer Card through Service Bay Technical System (SBTS). Once the card is inserted into the NGS Tester and the cable is connected, follow the calibration download instructions displayed on the NGS screen. The 15- to 104-Pin Flash Cable (007-00587) can be ordered from Rotunda by calling 1-800-ROTUNDA. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-26-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 206000, 290000, 690000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-22-8 > Nov > 09 > Exhaust System - Broken Exhaust Manifold Studs Engine Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-22-8 > Nov > 09 > Exhaust System - Broken Exhaust Manifold Studs > Page 3987 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 09-22-8 > Nov > 09 > Exhaust System - Broken Exhaust Manifold Studs > Page 3988 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3989 Engine Control Module: Specifications Powertrain Control Module (PCM) Connector Screws 4.5 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3992 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3993 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3994 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3995 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3996 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3997 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3998 Engine Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3999 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4000 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4001 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4002 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4003 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4004 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4005 Engine Control Module: Connector Views Diagram 25-9 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4006 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4007 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 4008 Engine Control Module: Description and Operation The powertrain control module needs the following inputs to calibrate the engine properly: ^ camshaft position. ^ engine rpm. ^ engine coolant temperature. ^ amount of engine detonation. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures Engine Control Module: Procedures Flash Electrically Erasable Programmable Read Only Memory is contained in an Integrated Circuit (IC) internally to the PCM. The EEPROM contains the vehicle strategy as well as any calibration information specific to the vehicle. The IC is reprogrammable and at times it may become necessary to reprogram or reflash the entire contents. This is usually due to either an after production strategy change or the Vehicle Identification (VID) area has been previously reprogrammed and has reached its limit. The VID block area can be tailored to accommodate various hardware changes made to the vehicle since production. The VID block is a section of memory within the IC which includes items such as octane adjust, fuel octane, fuel type, tire size and axle ratio. Programming a Replacement PCM A replacement PCM will display a label as shown. This indicates the need to retrieve VID data from the original PCM before removing from the vehicle. Refer to the flash VID block update procedure. After retrieving the VID data from the original PCM, install the new PCM. Select "Restore PCM config. (1)" to download the stored data. If the original PCM is nonfunctional, it becomes necessary to manually reprogram the VID block. The scan tool is used to perform this procedure and is done through the "PCM Programming" selection as described by the flash EEPROM procedure below. Follow screen instructions. Flash EEPROM Procedure When using the NGS to reprogram the entire IC contents, the NGS Flash kit will be used. The Service Bay Technical System (SBTS) is used to download the new strategy with calibration onto the NGS static RAM card (data transfer card). The card is part of the flash kit. Plug the NGS flash cable into the underdash OBD II connector. Follow the NGS screen instructions under "PCM Programming" or refer to the flash instruction manual provided in the kit. VID block information can also be viewed and changed during this procedure. Flash VID Block Procedure When using the NGS scan tool, the Ford Service Function (FSF) card is used along with the NGS flash cable. Plug the cable into the underdash OBD II connector. From the main menu, select "Service Bay Functions", "PCM-Powertrain Control Module" and then "Programmable Module Installation". The screen will now display two selections. The first is for old PCM information to be retrieved and stored within the NGS. The second is for restoring the new PCM with information which has been retrieved from the old PCM. Follow screen instructions or refer to the supplement instruction sheet included with the Ford Service Function card. Next, either a transfer of data from the old module to the new module or a manual update must be performed on the VID block. Follow screen instructions or refer to the supplement instruction sheet included with the Ford Service Function card. If the VID block has been reprogrammed previously, the scan tool will display a message. This message will indicate the need to reflash the entire IC. NOTE: If using a generic scan tool, follow the instruction manual provided by the tool manufacturer. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 4011 Engine Control Module: Reset Procedure Purpose for Clearing Codes Resetting Keep Alive RAM will return PCM memory to its default setting. Adaptive learning contents such as idle and fuel trim are included. A PCM Reset is also part of a KAM Reset. After Keep Alive RAM has been reset, the vehicle may exhibit certain driveability concerns. It will be necessary to drive the vehicle to allow the PCM to relearn values for optimum driveability and performance. A Keep Alive Random Access Memory Reset is done as follows: During Key ON, Engine OFF with the scan tool, use the Reset Keep Alive Memory function. This is found in the Active Command Modes menu on the New Generation Star scan tool. If a generic scan tool is used, this function may not be supported. Refer to scan tool manufacturer's instruction manual. If an error message is received or the scan tool does not support this function, disconnecting the battery ground cable for a minimum of 5 minutes may be used as an alternative procedure. Powertrain Control Module (PCM/KAM Reset) All OBDII scan tools support the Powertrain Control Module (PCM) reset. The PCM Reset allows the scan tool to command the PCM to clear all emission-related diagnostic information. When resetting the PCM, a DTC P1000 will be stored in the PCM until all the OBD II system monitors or components have been tested to satisfy a drive cycle, without any other faults occurring. The following events occur when a PCM reset is performed: - Clears the number of Diagnostic Trouble Codes (DTCs). - Clears the DTCs. - Clears the freeze frame data. - Clears diagnostic monitoring test results. - Resets status of the OBD II system monitors. - Sets DTC P1000. NOTE: When using the New Generation Star (NGS) Scan Tool to perform a PCM reset, press the CLEAR button. This function is performed only after retrieval of continuous DTCs. New Generation Star and Generic Scan Tool Refer to the scan tool manufacturer's manual for specific instructions on how to perform PCM reset. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 4012 Engine Control Module: Removal and Replacement REMOVAL 1. Remove the battery and battery tray. 2. Loosen the bolt and separate the PCM electrical connectors. 3. Remove the RH front door scuff plate. 4. Remove the RH cowl side trim panel. 5. Remove the PCM bracket clip. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 4013 6. Remove the powertrain control module. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications Engine Temperature Sensor: Specifications Cylinder Head Temperature (CHT) Sensor 6.9-13.5 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications > Page 4017 Engine Temperature Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Remove the Cylinder Head Temperature (CHT) sensor. 1 Disconnect the connector. 2 Remove the CHT sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service and Repair Fuel Tank Pressure Sensor: Service and Repair REMOVAL 1. Remove the fuel tank. 2. Disconnect the electrical connector. CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Push down while rotating the sensor counterclockwise to disengage it from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. 3. Press down and rotate the fuel tank pressure sensor counterclockwise and remove it from the fuel tank. INSTALLATION 1. To install, reverse the removal procedure. 2. Leak test the system. 3. Carry out the Evaporative Emission Running Loss Monitor Repair Verification Drive Cycle Test. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications Idle Speed/Throttle Actuator - Electronic: Specifications Idle Air Control (IAC) Valve Screws 8-10 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 4024 Idle Speed/Throttle Actuator - Electronic: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the shield. 3. Remove the idle air control valve. 1 Disconnect the electrical connector. 2 Disconnect the throttle bypass hose. 3 Remove the bolts. 4 Remove the IAC valve. 5 Remove and discard the IAC valve gasket. INSTALLATION 1. Install the idle air control valve. 1 Position the IAC valve and gasket. 2 Install the bolts in two stages: 8-10 N.m (71-89 Lb/In) - Tighten them an additional 85-95 degrees. NOTE: A new IAC valve gasket must be installed. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 4025 2. Connect the throttle bypass hose and the IAC electrical connector. 3. Install the accelerator control splash shield. 4. Connect the battery ground cable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions Information Bus: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4031 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4032 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4033 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4034 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4035 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4036 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4037 Information Bus: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4038 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4039 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4040 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4041 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4042 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4043 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 4044 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > Module Communication Network Information Bus: Description and Operation Module Communication Network Principles of Operation The vehicle has two module communications networks. The Standard Corporate Protocol (SCP) which is an unshielded twisted pair cable (data bus plus, Circuit 914 [TN/OG] and data bus minus, Circuit 915 [PK/LB]), and the International Standards Organization (ISO) 9141 network which is a single wire (Circuit 70 [LB/WH]). The New Generation STAR (NGS) Tester can connect to both networks through the Data Link Connector (DLC). This makes diagnosis and testing of these systems easier by allowing one smart tester to be able to diagnose and control any module on the two networks from one connector. The DLC can be found under the instrument panel between the steering column and the radio. The ISO 9141 communication network does not permit inter-module communication. When the NGS Tester communicates to modules on the ISO 9141 communication network, the NGS Tester must ask for all information; the modules cannot initiate communications. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > Module Communication Network > Page 4047 The SCP network will remain operational even with the severing of one of the bus wires. Communications will also continue if one of the bus wires is shorted to ground or battery positive voltage (B+) or if some, but not all, termination resistors are lost. Unlike the SCP communication network, the ISO 9141 communication network will not function if the wire is shorted to chassis ground or battery positive voltage (B+). Also, if one of the modules on the ISO 9141 network loses power or shorts internally, communications to that module will fail. The Powertrain Control Module (PCM) is on the SCP communication network. The PCM controls the engine for better fuel economy, emissions control, and failure mode detection and storage. The Natural Gas Vehicle Module (NGVM) calculates fuel level based on inputs from the fuel tank pressure sensor and the fuel tank temperature sensor. The NGVM then provides a voltage signal to the instrument cluster to drive the fuel gauge. The NGVM also has separate injector drivers to run the injectors at the higher operating pressure of natural gas. The NGVM does not perform any calculations for this function; calibration for the injectors is maintained in the PCM. The Restraint Control Module (RCM) is on the ISO 9141 network. The RCM controls the deployment of the air bags based on sensor input. The Generic Electronic Module (GEM) and the Central Timer Module (CTM) are on the ISO 9141 network. Only one GEM or one CTM will be on a vehicle. The GEM is equipped on vehicles with 4-wheel drive or vehicles with power windows. The CTM is equipped on vehicles with 2-wheel drive and vehicles without power windows. The GEM controls additional functions that include: - Speed dependent windshield wipers. - 4-wheel shift on the fly. - One touch down power window. The Remote Anti-Theft Personality (RAP) module is on the ISO 9141 communication network. The RAP module controls keyless entry for the vehicle. The 4-wheel anti-lock brake control module is on the ISO 9141 communication network. The 4-wheel anti-lock brake control module controls the brake pressure to the four wheels to keep the vehicle under control while braking. The instrument cluster is also known as a Hybrid Electronic Cluster (HEC) and is on the SCP communication network. The instrument cluster displays driver information. The instrument cluster incorporates the PATS control module functions. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Description and Operation > Module Communication Network > Page 4048 Information Bus: Description and Operation Module Configuration NOTE - Newly released modules will require configuration after being installed on the vehicle. All configurable modules will be packaged in a kit which contains a warning label and a multi-language sheet re-emphasizing the requirements to configure replacement modules. - The Powertrain Control Module (PCM) has to be flash programmed using a flash cable. Customer Driven Preferences There are customer preference items that can or need to be configured on this vehicle. These are items that the customer may or may not want to have enabled. Typically, customer preference items can be toggled on or off by the use of a Ford compatible scan tool. You may need to ask the customer which preferences they had enabled prior to installation of the new module. To carry out the customer configuration process, use a Ford Service Function (FSF) card and the New Generation STAR (NGS) Tester. Refer to the Customer Preference Index for modules on the vehicle that have customer preference items. Configure the items as needed with a Ford compatible scan tool. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis Information Bus: Flow of Diagnosis Module Communication Network 1. Verify the customer concern. 2. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical Central Junction Box (CJB) Fuse 3 (25 A) - Damaged wiring harness - Loose or corroded connections - 4-wheel anti-lock brake control module - Remote Anti-Theft Personality (RAP) module - Generic Electronic Module (GEM)/Central Timer Module (CTM) - Restraint control module (RCM) - Powertrain control module (PCM) - Natural gas vehicle module (NGVM) - Instrument cluster 3. If the concern remains after the inspection, connect New Generation STAR (NGS) Tester to the Data Link Connector (DLC), located beneath the instrument panel, and select the vehicle to be tested from NGS Tester menu. If NGS Tester does not communicate with the vehicle: Check that the program card is properly installed and the correct version is used. - Check the connections to the vehicle. - Check the ignition switch position. If NGS Tester still does not communicate with the vehicle, go to Pinpoint Test J. See: Pinout Values and Diagnostic Parameters/Module Communication Network/Pinpoint Tests/J: Module/Network Communication - No Power to the NGS Tester 4. Go to Pinpoint Test PC. See: Pinout Values and Diagnostic Parameters/Module Communication Network/System Precheck Module Configuration 1. Visually inspect for obvious signs of electrical damage. Refer to the following chart: VISUAL INSPECTION CHART Electrical Central Junction Box (CJB) Fuse 3 (20 A). - Damaged wiring harness - Loose or corroded connectors - Generic Electronic Module (GEM) - Remote Anti-Theft Personality (RAP) module - Instrument cluster 2. If the concern remains after inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from NGS Tester menu. If NGS Tester does not communicate with the vehicle: check that the program card is correctly installed. - check the connections to the vehicle. check the ignition switch is in RUN position. 3. If the NGS Tester still will not communicate with the vehicle, Refer to the Symptom Chart. See: Pinout Values and Diagnostic Parameters/Module Configuration/Symptom Chart Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4051 Information Bus: Pinout Values and Diagnostic Parameters Inspection and Verification (Start Here) 1. Verify the customer concern. 2. Visually inspect for obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical Central Junction Box (CJB) Fuse 3 (25 A) - Damaged wiring harness - Loose or corroded connections - 4-wheel anti-lock brake control module - Remote Anti-Theft Personality (RAP) module - Generic Electronic Module (GEM)/Central Timer Module (CTM) - Restraint control module (RCM) - Powertrain control module (PCM) - Natural gas vehicle module (NGVM) - Instrument cluster 3. If the concern remains after the inspection, connect New Generation STAR (NGS) Tester to the Data Link Connector (DLC), located beneath the instrument panel, and select the vehicle to be tested from NGS Tester menu. If NGS Tester does not communicate with the vehicle: Check that the program card is properly installed and the correct version is used. - Check the connections to the vehicle. - Check the ignition switch position. If NGS Tester still does not communicate with the vehicle, go to Pinpoint Test J. See: Module Communication Network/Pinpoint Tests/J: Module/Network Communication - No Power to the NGS Tester 4. Go to Pinpoint Test PC. See: Module Communication Network/System Precheck Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4052 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4053 A1 - A2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4054 A3 - A4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4055 B1 - B2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4056 B3 - B4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4057 C1 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4058 D1 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4059 E1 - E2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4060 E3 - E4 F: Natural Gas Veh. Module (NGVM) Doesn't Respond To NGS Tester Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4061 F1 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4062 F2 - F3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4063 F4 G: Module/Network Communication - ISO 9141 Comm. Network Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4064 G1 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4065 G2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4066 G3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4067 G4 - G5 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4068 G6 - G7 H: Module/Network Communication - SCP Communication Network Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4069 H1 - H2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4070 H3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4071 H4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4072 H5 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4073 H6 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4074 H7 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4075 I1 - I2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4076 J1 - J2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4077 J3 - J4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4078 Inspection and Verification (Start Here) 1. Visually inspect for obvious signs of electrical damage. Refer to the following chart: VISUAL INSPECTION CHART Electrical Central Junction Box (CJB) Fuse 3 (20 A). - Damaged wiring harness - Loose or corroded connectors - Generic Electronic Module (GEM) - Remote Anti-Theft Personality (RAP) module - Instrument cluster 2. If the concern remains after inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from NGS Tester menu. If NGS Tester does not communicate with the vehicle: check that the program card is correctly installed. - check the connections to the vehicle. check the ignition switch is in RUN position. If the NGS Tester still will not communicate with the vehicle. 3. Refer to the Symptom Chart. See: Module Configuration/Symptom Chart Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4079 A1 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Page 4080 Information Bus: Service and Repair Communication Circuit Wiring Repair Heat Gun Special Tool(s) 1. Disconnect the battery ground cable. 2. Strip the wires. 3. Solder the wires. 1 Install the heat shrink tube. 2 Twist the wires together. 3 Solder the wires together. NOTE: Use Rosin Core Mildly Activated (RMA) solder, not acid core solder. 4. Bend the wires back in a straight line. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Page 4081 NOTE: Wait for the solder to cool before moving the wires. 5. Position the (A) heat shrink tube over the (B) wire repair. - Overlap the heat shrink tube on both wires. 6. Use Heat Gun to heat the repaired area until adhesive flows out both ends of the heat shrink tube. 7. Reconnect the battery ground cable. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Linear Knock Sensor 16.2-23.8 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 4085 Knock Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Remove the knock sensor. 1 Disconnect the connector. 2 Remove the knock sensor. NOTE: This engine is equipped with a unique linear knock sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4089 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay Main Relay (Computer/Fuel System): Testing and Inspection PCM Power Relay Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay > Page 4092 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Testing and Inspection Malfunction Indicator Lamp: Testing and Inspection Refer to Instrument Panel/Testing and Inspection/Procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics Oxygen Sensor: Technical Service Bulletins Engine Controls - Bi-Fuel O2 Sensor Diagnostics Article No. 03-6-6 03/31/03 DRIVEABILITY - BI-FUEL - OXYGEN SENSOR DIAGNOSTICS - HIGH OXYGEN SENSOR VOLTAGE READING FORD: 1998-2000 CONTOUR 1998-1999 E SERIES 1998-2003 F-150 1999 F-250 ISSUE Some Bi-Fuel vehicles may exhibit DTC's for high Oxygen Sensor voltage (P0132 and P0152). Current diagnostics may result in premature replacement of the Compuvalve. ACTION If an Oxygen Sensor code is set, the current diagnostics direct the Compuvalve to be replaced it no faults are detected when Pinpoint Test H is conducted. The modified repair action outlined below gives additional test procedures if nothing is detected from Pinpoint Test H. SERVICE PROCEDURE 1. Prior to clearing any codes, to aid in diagnostics of intermittent failures, access and record the freeze frame data using the NGS Tester. 2. At step H4 of the pinpoint test, it Oxygen Sensor PIDS (H02S11 and H02521) are within specification (see table in Section H of PC/ED Manual), clear codes and road test the vehicle in alternative fuel using the freeze frame data (from above) to duplicate conditions that triggered the code. During the road test, monitor Oxygen Sensor PIDs for both banks in both the PCM and the AFCM. NOTE A SECOND TECHNICIAN SHOULD MONITOR THE PIDS WHILE THE OTHER DRIVES. IF THE CODE/CONCERN CANNOT BE DUPLICATED, REFER TO PINPOINT TEST Z OF THE BASE VEHICLE PC/ED. 3. If the concern is duplicated, and if voltage is outside of specifications in both the AFCM and the PCM, the fault is in the Heated Exhaust Gas Oxygen (HEGO) sensor circuit. Refer to base vehicle diagnostics. 4. If the voltage is outside of specifications in the AFCM only, replace the Compuvalve. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 490000, 698298 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4100 Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4101 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4102 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4103 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4104 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4105 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4106 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4107 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4108 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4109 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4110 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4111 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4112 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4113 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4114 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4115 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 4116 Oxygen Sensor: Specifications Heated Oxygen Sensor (HO2S) 36-46 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > OBD-II Heated Oxygen Sensor Numbering Convention Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > OBD-II Heated Oxygen Sensor Numbering Convention > Page 4119 Oxygen Sensor: Locations Component Location 4.2L/4.6L 5.4L/6.8L Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4122 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4123 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4124 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4125 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4126 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4127 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4128 Oxygen Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4129 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4130 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4131 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4132 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4133 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4134 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4135 Oxygen Sensor: Connector Views Oxygen Sensor Vehicle Harness Connector PCM Connector Pin Numbers Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) - Front Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) - Front Oxygen Sensor Wrench Special Tool(s) REMOVAL WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. NEVER ATTEMPT TO SERVICE ANY PART OF THE SYSTEM UNTIL IT HAS COOLED. BE ESPECIALLY CAREFUL WHEN WORKING AROUND THE THREE WAY CATALYTIC CONVERTER. THE TEMPERATURE OF THE THREE WAY CATALYTIC CONVERTER RISES TO A HIGH LEVEL AFTER ONLY A FEW MINUTES OF ENGINE OPERATION. 1. Turn the ignition switch OFF. 2. Disconnect the connector. 3. Raise and support the vehicle. 4. Use Oxygen Sensor Wrench to remove the heated oxygen sensor. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) - Front > Page 4138 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) - Front > Page 4139 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) - Rear Oxygen Sensor Wrench Special Tool(s) REMOVAL WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. NEVER ATTEMPT TO SERVICE ANY PART OF THE SYSTEM UNTIL IT HAS COOLED. BE ESPECIALLY CAREFUL WHEN WORKING AROUND THE THREE WAY CATALYTIC CONVERTER. THE TEMPERATURE OF THE THREE WAY CATALYTIC CONVERTER RISES TO A HIGH LEVEL AFTER ONLY A FEW MINUTES OF ENGINE OPERATION. 1. Turn the ignition switch OFF. 2. Raise and support the vehicle. 3. Remove the heated oxygen sensor. 1 Disconnect the connector. 2 Use the Oxygen Sensor Wrench to remove the heated oxygen sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications Pressure Feedback Exhaust Sensor: Specifications Differential Pressure Feedback EGR Sensor Nuts 8-12 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 4143 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Remove the differential pressure feedback EGR sensor. 1 Remove the differential pressure feedback EGR sensor tubes. 2 Disconnect the differential pressure feedback EGR sensor electrical connector. 3 Remove the two nuts. 4 Remove the differential pressure feedback EGR sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Alternative Fuel Control Module > Component Information > Technical Service Bulletins > Bi-Fuel System - Compuvalve Replacement Alternative Fuel Control Module: Technical Service Bulletins Bi-Fuel System - Compuvalve Replacement Article No. 01-10-6 05/28/01 DRIVEABLITY - BI-FUEL - COMPUVALVE PRE-REPLACEMENT CHECK LIST - SERVICE TIPS FORD: 1996-2000 CONTOUR 1994-2001 F-150, F-250 LD 1995-2001 E-250, E-350 1999-2001 SUPER DUTY F SERIES ISSUE This article will be used as an aid in diagnosis to avoid unnecessary replacement of the compuvalve on bi-fuel vehicles after normal diagnosis has determined the compuvalve may be faulty. ACTION Complete the normal diagnostic methods and pinpoint tests. Should the conclusion be after normal diagnosis to replace the compuvalve, then follow the compuvalve Pre-Replacement Checklist (below) before replacing the compuvalve. SERVICE INFORMATION Glossary Of Terms ^ ALT - Alternate Fuel Mode ^ FAP - Fuel Absolute Pressure ^ HPS - High Pressure Solenoid ^ VCL - Vehicle Communications Link ^ AFCM - Alternate Fuel Control Module ^ WDS - Worldwide Diagnostic System ^ DTC - Diagnostic Trouble Code ^ MAP - Manifold Absolute Pressure ^ LPG - Liquid Propane Gas ^ EEC - Electronic Engine Control NOTE THE FOLLOWING IS A LIST OF KNOWN MIS-DIAGNOSIS OF THE COMPUVALVE REPLACEMENT ON BI-FUEL VEHICLES. 1. MAP line loose. 2. High FAP from vaporizer breakdown. 3. Incorrect interpretation of DTCs. 4. VCL replacement due to harness faults. 5. Misfire due to leaking 0-rings. 6. Compuvalve replaced without checking HPS circuit for correct resistance. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Alternative Fuel Control Module > Component Information > Technical Service Bulletins > Bi-Fuel System - Compuvalve Replacement > Page 4149 7. Low FAP due to lockoff fault. 8. LPG fuel filter in backward. COMPUVALVE PRE-REPLACEMENT CHECKLIST 1. Check communication ability with EEC, AFCM/compuvalve and VCL and compuvalve. Follow the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual procedures for the appropriate vehicle. 2. Check MAP line. Follow normal diagnostic methods and visual checks. 3. Check harness and connection integrity. Follow normal diagnostic methods, basic circuit checks and harness connections. 4. Check current bi-fuel EEC calibration code. Refer to WDS. 5. Check fuel gauge with fuel selector switch in ALT position for fuel level. 6. Check power to compuvalve. Power to the compuvalve is indicated by the following fuel selector switch light status: On steady = OK, On then Off or Flashing (regular and irregular) indicated fault. 7. Check that the arrow on the LPG fuel filter is pointing in the direction of fuel flow. 8. Check base vehicle. Run vehicle in gas mode (e.g., borderline secondary ignition). Follow normal diagnostic methods. 9. Check other applicable TSBs and special service messages. 10. Verify ALT fuel switch status. Refer to Section 1 of the appropriate PC/ED Workshop Manual. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 490000, 602300, 603300, 608000, 609000, 611000, 623000, 690000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 4158 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 4159 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 4160 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures Engine Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 4166 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 4167 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 4172 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 4173 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 4174 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 99-4-3 > Mar > 99 > PCM - Reprogramming Out of Vehicle Engine Control Module: All Technical Service Bulletins PCM - Reprogramming Out of Vehicle Article No. 99-4-3 03/08/99 REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS) - OUT-OF-VEHICLE - EEC V VEHICLES ONLY FORD: 1994-97 THUNDERBIRD 1994-99 MUSTANG 1995-99 CROWN VICTORIA 1996-97 PROBE 1996-99 CONTOUR, ESCORT, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR 1995-99 CONTINENTAL, GRAND MARQUIS, TOWN CAR 1996-98 MARK VIII 1996-99 MYSTIQUE, SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1994-97 F SUPER DUTY, F-250 HD, F-350 1995-99 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-97 AEROSTAR 1996-99 EXPLORER, F-150, F-250 LD 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to update the affected vehicles and to include an Application Chart for the affected vehicles. ISSUE The Federal Environmental Protection Agency (EPA) has mandated that all aftermarket service centers shall be able to either reprogram Powertrain Control Modules (PCMs) or obtain reasonably priced, timely PCM programming services at dealerships. Ford has released an out-of-vehicle EEC V reprogramming cable to support this requirement. Also, PCMs are reprogrammable to update calibration levels or to reprogram a common hardware type to a new calibration in order to fill a service need without ordering a new PCM. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 99-4-3 > Mar > 99 > PCM - Reprogramming Out of Vehicle > Page 4179 ACTION Refer to the Application Chart in this article to use the new 15- to 104-Pin Flash Cable to handle all necessary out-of-vehicle programming of EEC V modules in the vehicles listed. This may allow added flexibility in servicing aftermarket and fleet accounts as well as provide the ability to have modules updated to new calibrations through the Parts Department instead of ordering new parts. Currently, EEC V modules must be installed in a vehicle to reprogram a new calibration in the module. An aftermarket service center may bring a module to a dealership for a calibration update or may request an updated calibration be installed to a new service part. The EPA regulations require "reasonably priced, timely service" be provided by the dealer. The new 15- to 104-Pin Flash Cable works with the New Generation Star (NGS) Tester to provide the capability to reprogram a calibration on a PCM out of the vehicle. The 15- to 104-Pin Flash Cable connects between the NGS Tester and PCM 104-pin connector. The proper calibration must be downloaded to the Data Transfer Card through Service Bay Technical System (SBTS). Once the card is inserted into the NGS Tester and the cable is connected, follow the calibration download instructions displayed on the NGS screen. The 15- to 104-Pin Flash Cable (007-00587) can be ordered from Rotunda by calling 1-800-ROTUNDA. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-26-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 206000, 290000, 690000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures Engine Control Module: All Technical Service Bulletins Engine Controls - General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 4185 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 4186 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 99-4-3 > Mar > 99 > PCM - Reprogramming Out of Vehicle Engine Control Module: All Technical Service Bulletins PCM - Reprogramming Out of Vehicle Article No. 99-4-3 03/08/99 REPROGRAMMING POWERTRAIN CONTROL MODULES (PCMS) - OUT-OF-VEHICLE - EEC V VEHICLES ONLY FORD: 1994-97 THUNDERBIRD 1994-99 MUSTANG 1995-99 CROWN VICTORIA 1996-97 PROBE 1996-99 CONTOUR, ESCORT, TAURUS LINCOLN-MERCURY: 1994-97 COUGAR 1995-99 CONTINENTAL, GRAND MARQUIS, TOWN CAR 1996-98 MARK VIII 1996-99 MYSTIQUE, SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1994-97 F SUPER DUTY, F-250 HD, F-350 1995-99 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-97 AEROSTAR 1996-99 EXPLORER, F-150, F-250 LD 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to update the affected vehicles and to include an Application Chart for the affected vehicles. ISSUE The Federal Environmental Protection Agency (EPA) has mandated that all aftermarket service centers shall be able to either reprogram Powertrain Control Modules (PCMs) or obtain reasonably priced, timely PCM programming services at dealerships. Ford has released an out-of-vehicle EEC V reprogramming cable to support this requirement. Also, PCMs are reprogrammable to update calibration levels or to reprogram a common hardware type to a new calibration in order to fill a service need without ordering a new PCM. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 99-4-3 > Mar > 99 > PCM - Reprogramming Out of Vehicle > Page 4191 ACTION Refer to the Application Chart in this article to use the new 15- to 104-Pin Flash Cable to handle all necessary out-of-vehicle programming of EEC V modules in the vehicles listed. This may allow added flexibility in servicing aftermarket and fleet accounts as well as provide the ability to have modules updated to new calibrations through the Parts Department instead of ordering new parts. Currently, EEC V modules must be installed in a vehicle to reprogram a new calibration in the module. An aftermarket service center may bring a module to a dealership for a calibration update or may request an updated calibration be installed to a new service part. The EPA regulations require "reasonably priced, timely service" be provided by the dealer. The new 15- to 104-Pin Flash Cable works with the New Generation Star (NGS) Tester to provide the capability to reprogram a calibration on a PCM out of the vehicle. The 15- to 104-Pin Flash Cable connects between the NGS Tester and PCM 104-pin connector. The proper calibration must be downloaded to the Data Transfer Card through Service Bay Technical System (SBTS). Once the card is inserted into the NGS Tester and the cable is connected, follow the calibration download instructions displayed on the NGS screen. The 15- to 104-Pin Flash Cable (007-00587) can be ordered from Rotunda by calling 1-800-ROTUNDA. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-26-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 206000, 290000, 690000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 4192 Engine Control Module: Specifications Powertrain Control Module (PCM) Connector Screws 4.5 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4195 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4196 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4197 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4198 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4199 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4200 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4201 Engine Control Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4202 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4203 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4204 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4205 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4206 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4207 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4208 Engine Control Module: Connector Views Diagram 25-9 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4209 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4210 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Page 4211 Engine Control Module: Description and Operation The powertrain control module needs the following inputs to calibrate the engine properly: ^ camshaft position. ^ engine rpm. ^ engine coolant temperature. ^ amount of engine detonation. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures Engine Control Module: Procedures Flash Electrically Erasable Programmable Read Only Memory is contained in an Integrated Circuit (IC) internally to the PCM. The EEPROM contains the vehicle strategy as well as any calibration information specific to the vehicle. The IC is reprogrammable and at times it may become necessary to reprogram or reflash the entire contents. This is usually due to either an after production strategy change or the Vehicle Identification (VID) area has been previously reprogrammed and has reached its limit. The VID block area can be tailored to accommodate various hardware changes made to the vehicle since production. The VID block is a section of memory within the IC which includes items such as octane adjust, fuel octane, fuel type, tire size and axle ratio. Programming a Replacement PCM A replacement PCM will display a label as shown. This indicates the need to retrieve VID data from the original PCM before removing from the vehicle. Refer to the flash VID block update procedure. After retrieving the VID data from the original PCM, install the new PCM. Select "Restore PCM config. (1)" to download the stored data. If the original PCM is nonfunctional, it becomes necessary to manually reprogram the VID block. The scan tool is used to perform this procedure and is done through the "PCM Programming" selection as described by the flash EEPROM procedure below. Follow screen instructions. Flash EEPROM Procedure When using the NGS to reprogram the entire IC contents, the NGS Flash kit will be used. The Service Bay Technical System (SBTS) is used to download the new strategy with calibration onto the NGS static RAM card (data transfer card). The card is part of the flash kit. Plug the NGS flash cable into the underdash OBD II connector. Follow the NGS screen instructions under "PCM Programming" or refer to the flash instruction manual provided in the kit. VID block information can also be viewed and changed during this procedure. Flash VID Block Procedure When using the NGS scan tool, the Ford Service Function (FSF) card is used along with the NGS flash cable. Plug the cable into the underdash OBD II connector. From the main menu, select "Service Bay Functions", "PCM-Powertrain Control Module" and then "Programmable Module Installation". The screen will now display two selections. The first is for old PCM information to be retrieved and stored within the NGS. The second is for restoring the new PCM with information which has been retrieved from the old PCM. Follow screen instructions or refer to the supplement instruction sheet included with the Ford Service Function card. Next, either a transfer of data from the old module to the new module or a manual update must be performed on the VID block. Follow screen instructions or refer to the supplement instruction sheet included with the Ford Service Function card. If the VID block has been reprogrammed previously, the scan tool will display a message. This message will indicate the need to reflash the entire IC. NOTE: If using a generic scan tool, follow the instruction manual provided by the tool manufacturer. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 4214 Engine Control Module: Reset Procedure Purpose for Clearing Codes Resetting Keep Alive RAM will return PCM memory to its default setting. Adaptive learning contents such as idle and fuel trim are included. A PCM Reset is also part of a KAM Reset. After Keep Alive RAM has been reset, the vehicle may exhibit certain driveability concerns. It will be necessary to drive the vehicle to allow the PCM to relearn values for optimum driveability and performance. A Keep Alive Random Access Memory Reset is done as follows: During Key ON, Engine OFF with the scan tool, use the Reset Keep Alive Memory function. This is found in the Active Command Modes menu on the New Generation Star scan tool. If a generic scan tool is used, this function may not be supported. Refer to scan tool manufacturer's instruction manual. If an error message is received or the scan tool does not support this function, disconnecting the battery ground cable for a minimum of 5 minutes may be used as an alternative procedure. Powertrain Control Module (PCM/KAM Reset) All OBDII scan tools support the Powertrain Control Module (PCM) reset. The PCM Reset allows the scan tool to command the PCM to clear all emission-related diagnostic information. When resetting the PCM, a DTC P1000 will be stored in the PCM until all the OBD II system monitors or components have been tested to satisfy a drive cycle, without any other faults occurring. The following events occur when a PCM reset is performed: - Clears the number of Diagnostic Trouble Codes (DTCs). - Clears the DTCs. - Clears the freeze frame data. - Clears diagnostic monitoring test results. - Resets status of the OBD II system monitors. - Sets DTC P1000. NOTE: When using the New Generation Star (NGS) Scan Tool to perform a PCM reset, press the CLEAR button. This function is performed only after retrieval of continuous DTCs. New Generation Star and Generic Scan Tool Refer to the scan tool manufacturer's manual for specific instructions on how to perform PCM reset. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 4215 Engine Control Module: Removal and Replacement REMOVAL 1. Remove the battery and battery tray. 2. Loosen the bolt and separate the PCM electrical connectors. 3. Remove the RH front door scuff plate. 4. Remove the RH cowl side trim panel. 5. Remove the PCM bracket clip. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Service and Repair > Procedures > Page 4216 6. Remove the powertrain control module. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4220 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay Main Relay (Computer/Fuel System): Testing and Inspection PCM Power Relay Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay > Page 4223 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4233 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4234 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4240 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4241 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 4242 Air Flow Meter/Sensor: Specifications Mass Airflow Sensor (MAF) Plate Nuts 8-11.5 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 4243 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 4244 Air Flow Meter/Sensor: Service and Repair REMOVAL WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. THE SENSOR CAN BE DAMAGED BY TOUCHING. 1. Disconnect the battery ground cable. 2. Open the engine air cleaner. ^ Disconnect the Mass Air Flow (MAF) sensor connector from the wiring harness. ^ Release the air cleaner clamp. ^ Separate the inlet side of the air cleaner from the outlet side of the air cleaner. 3. Cut the tape on the wire loom of the extension harness. ^ Peel back the wire loom from the extension harness near the grommet in the air cleaner. CAUTION: Do not cut the MAF sensor wires when cutting the tape on the wire loom. 4. Remove the grommet from the outlet side of the air cleaner and slide the grommet down the extension harness. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 4245 5. Remove the MAF sensor plate and mass air flow sensor from the outlet side of the engine air cleaner. 6. Disconnect the MAF sensor connector. 7. Remove the nuts and separate the MAF plate from the mass air flow sensor. INSTALLATION 1. Follow the removal procedure in reverse order. CAUTION ^ Do not tamper with the MAF sensing elements located in the airflow bypass; tampering may result in unit failure. ^ The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. NOTE ^ The MAF sensor module and body are calibrated and replaced as a unit. ^ Use the alignment notch to properly align the inlet side and the outlet side of the engine air cleaner. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4254 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4255 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4256 DISCLAIMER Service Procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4257 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4258 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4259 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4260 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4261 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4262 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4263 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4264 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4265 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4266 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4272 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4273 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4274 DISCLAIMER Service Procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4275 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4276 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4277 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4278 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4279 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4280 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4281 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4282 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4283 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4284 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 4285 Camshaft Position Sensor: Specifications Camshaft Position (CMP) Sensor Bolt 8-12 Nm Camshaft Position Sensor 8-12 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 4286 Camshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Camshaft Position (CMP) sensor 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the camshaft position sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams > Page 4290 Clutch Switch: Service and Repair REMOVAL 1. Disconnect electrical connector from clutch pedal position switch. 2. Release the clutch pedal position switch from the orientation clip. 3. Remove the plastic retainer. 1 Push the lock tabs together. 2 Slide the plastic retainer off the clutch pedal position switch. 4. Remove the clutch pedal position switch. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications Coolant Temperature Sensor/Switch (For Computer): Specifications Engine Coolant Temperature Sensor (ECT) 16-24 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications Engine Temperature Sensor: Specifications Cylinder Head Temperature (CHT) Sensor 6.9-13.5 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Specifications > Page 4297 Engine Temperature Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Remove the Cylinder Head Temperature (CHT) sensor. 1 Disconnect the connector. 2 Remove the CHT sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Service and Repair Fuel Tank Pressure Sensor: Service and Repair REMOVAL 1. Remove the fuel tank. 2. Disconnect the electrical connector. CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be removed. Push down while rotating the sensor counterclockwise to disengage it from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel tank. 3. Press down and rotate the fuel tank pressure sensor counterclockwise and remove it from the fuel tank. INSTALLATION 1. To install, reverse the removal procedure. 2. Leak test the system. 3. Carry out the Evaporative Emission Running Loss Monitor Repair Verification Drive Cycle Test. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Service and Repair Intake Air Temperature Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the connector. 3. Remove the intake air temperature sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Linear Knock Sensor 16.2-23.8 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 4307 Knock Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Remove the knock sensor. 1 Disconnect the connector. 2 Remove the knock sensor. NOTE: This engine is equipped with a unique linear knock sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics Oxygen Sensor: Technical Service Bulletins Engine Controls - Bi-Fuel O2 Sensor Diagnostics Article No. 03-6-6 03/31/03 DRIVEABILITY - BI-FUEL - OXYGEN SENSOR DIAGNOSTICS - HIGH OXYGEN SENSOR VOLTAGE READING FORD: 1998-2000 CONTOUR 1998-1999 E SERIES 1998-2003 F-150 1999 F-250 ISSUE Some Bi-Fuel vehicles may exhibit DTC's for high Oxygen Sensor voltage (P0132 and P0152). Current diagnostics may result in premature replacement of the Compuvalve. ACTION If an Oxygen Sensor code is set, the current diagnostics direct the Compuvalve to be replaced it no faults are detected when Pinpoint Test H is conducted. The modified repair action outlined below gives additional test procedures if nothing is detected from Pinpoint Test H. SERVICE PROCEDURE 1. Prior to clearing any codes, to aid in diagnostics of intermittent failures, access and record the freeze frame data using the NGS Tester. 2. At step H4 of the pinpoint test, it Oxygen Sensor PIDS (H02S11 and H02521) are within specification (see table in Section H of PC/ED Manual), clear codes and road test the vehicle in alternative fuel using the freeze frame data (from above) to duplicate conditions that triggered the code. During the road test, monitor Oxygen Sensor PIDs for both banks in both the PCM and the AFCM. NOTE A SECOND TECHNICIAN SHOULD MONITOR THE PIDS WHILE THE OTHER DRIVES. IF THE CODE/CONCERN CANNOT BE DUPLICATED, REFER TO PINPOINT TEST Z OF THE BASE VEHICLE PC/ED. 3. If the concern is duplicated, and if voltage is outside of specifications in both the AFCM and the PCM, the fault is in the Heated Exhaust Gas Oxygen (HEGO) sensor circuit. Refer to base vehicle diagnostics. 4. If the voltage is outside of specifications in the AFCM only, replace the Compuvalve. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 490000, 698298 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4312 Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4313 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4314 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4315 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4316 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4317 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4318 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4319 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4320 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4321 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4322 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4323 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4324 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4325 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4326 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Engine Controls - Bi-Fuel O2 Sensor Diagnostics > Page 4327 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 4328 Oxygen Sensor: Specifications Heated Oxygen Sensor (HO2S) 36-46 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > OBD-II Heated Oxygen Sensor Numbering Convention Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > OBD-II Heated Oxygen Sensor Numbering Convention > Page 4331 Oxygen Sensor: Locations Component Location 4.2L/4.6L 5.4L/6.8L Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4334 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4335 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4336 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4337 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4338 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4339 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4340 Oxygen Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4341 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4342 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4343 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4344 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4345 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4346 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4347 Oxygen Sensor: Connector Views Oxygen Sensor Vehicle Harness Connector PCM Connector Pin Numbers Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) - Front Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) - Front Oxygen Sensor Wrench Special Tool(s) REMOVAL WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. NEVER ATTEMPT TO SERVICE ANY PART OF THE SYSTEM UNTIL IT HAS COOLED. BE ESPECIALLY CAREFUL WHEN WORKING AROUND THE THREE WAY CATALYTIC CONVERTER. THE TEMPERATURE OF THE THREE WAY CATALYTIC CONVERTER RISES TO A HIGH LEVEL AFTER ONLY A FEW MINUTES OF ENGINE OPERATION. 1. Turn the ignition switch OFF. 2. Disconnect the connector. 3. Raise and support the vehicle. 4. Use Oxygen Sensor Wrench to remove the heated oxygen sensor. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) - Front > Page 4350 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) - Front > Page 4351 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) - Rear Oxygen Sensor Wrench Special Tool(s) REMOVAL WARNING: THE NORMAL OPERATING TEMPERATURE OF THE EXHAUST SYSTEM IS VERY HIGH. NEVER ATTEMPT TO SERVICE ANY PART OF THE SYSTEM UNTIL IT HAS COOLED. BE ESPECIALLY CAREFUL WHEN WORKING AROUND THE THREE WAY CATALYTIC CONVERTER. THE TEMPERATURE OF THE THREE WAY CATALYTIC CONVERTER RISES TO A HIGH LEVEL AFTER ONLY A FEW MINUTES OF ENGINE OPERATION. 1. Turn the ignition switch OFF. 2. Raise and support the vehicle. 3. Remove the heated oxygen sensor. 1 Disconnect the connector. 2 Use the Oxygen Sensor Wrench to remove the heated oxygen sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications Pressure Feedback Exhaust Sensor: Specifications Differential Pressure Feedback EGR Sensor Nuts 8-12 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 4355 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Remove the differential pressure feedback EGR sensor. 1 Remove the differential pressure feedback EGR sensor tubes. 2 Disconnect the differential pressure feedback EGR sensor electrical connector. 3 Remove the two nuts. 4 Remove the differential pressure feedback EGR sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position (TP) Sensor Screws 2.8-3.4 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 4359 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the shield. 3. Remove the throttle position sensor. 1 Disconnect the connector. 2 Remove the bolts. 3 Remove the throttle position sensor. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 4360 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > 4R70W Transmission Position Switch/Sensor: Specifications Digital Transmission Range Sensor Bolts 7-10 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > 4R70W > Page 4365 Transmission Position Switch/Sensor: Specifications Digital Transmission TR Sensor 8-10 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4366 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W Transmission Position Switch/Sensor: Service and Repair 4R70W Special Tools 1. Raise and support vehicle. 2. Disconnect the manual lever shift control cable. 3. Disconnect the digital TR electrical connector. 4. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. The old nut will not retain torque specification. Remove the manual control lever. 1 Remove the nut. 2 Remove the lever. 5. Loosen the digital TR sensor bolts. 6. NOTE: Manual shift lever must be in the neutral position. Use digital transmission range TR Sensor Alignment Tool, to align the digital TR sensor slots. The tool is designed to fit snug. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W > Page 4369 7. Tighten the bolts. 8. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual lever shaft outer nut. 9. With the manual lever in overdrive connect the shift lever control cable. 10. Install the digital TR sensor electrical connector. 11. Lower the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W > Page 4370 Transmission Position Switch/Sensor: Service and Repair 4R100 Special Tools Removal 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Disconnect the connector. 4. Disconnect the shift cable at the manual control lever. 5. Remove the digital Transmission Range (TR) sensor. 1 Remove the bolts. 2 Remove the digital Transmission Range (TR) sensor. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W > Page 4371 1. Install the digital Transmission Range (TR) sensor. 1 Install digital Transmission Range (TR) sensor. 2 Loosely install the bolts. 2. NOTE: Make sure that the manual control lever is in the neutral position. Install the Digital Transmission Range (TR) Sensor Alignment Tool. The tool is designed to fit snug. 3. Tighten the bolts. 4. Reconnect the shift cable at the manual control lever. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W > Page 4372 5. Reconnect the connector. 6. Lower the vehicle. 7. Reconnect the battery ground cable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Tools and Equipment > 4R70W Special Tool Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Tools and Equipment > 4R70W > Page 4375 Special Tool Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications Vehicle Speed Sensor Bolt 11-13 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4381 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4382 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4383 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4384 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4385 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4386 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4387 Vehicle Speed Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4388 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4389 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4390 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4391 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4392 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4393 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position (TP) Sensor Screws 2.8-3.4 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 4397 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the shield. 3. Remove the throttle position sensor. 1 Disconnect the connector. 2 Remove the bolts. 3 Remove the throttle position sensor. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 4398 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > 4R70W Transmission Position Switch/Sensor: Specifications Digital Transmission Range Sensor Bolts 7-10 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > 4R70W > Page 4403 Transmission Position Switch/Sensor: Specifications Digital Transmission TR Sensor 8-10 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 4404 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W Transmission Position Switch/Sensor: Service and Repair 4R70W Special Tools 1. Raise and support vehicle. 2. Disconnect the manual lever shift control cable. 3. Disconnect the digital TR electrical connector. 4. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. The old nut will not retain torque specification. Remove the manual control lever. 1 Remove the nut. 2 Remove the lever. 5. Loosen the digital TR sensor bolts. 6. NOTE: Manual shift lever must be in the neutral position. Use digital transmission range TR Sensor Alignment Tool, to align the digital TR sensor slots. The tool is designed to fit snug. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W > Page 4407 7. Tighten the bolts. 8. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual lever shaft outer nut. 9. With the manual lever in overdrive connect the shift lever control cable. 10. Install the digital TR sensor electrical connector. 11. Lower the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W > Page 4408 Transmission Position Switch/Sensor: Service and Repair 4R100 Special Tools Removal 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Disconnect the connector. 4. Disconnect the shift cable at the manual control lever. 5. Remove the digital Transmission Range (TR) sensor. 1 Remove the bolts. 2 Remove the digital Transmission Range (TR) sensor. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W > Page 4409 1. Install the digital Transmission Range (TR) sensor. 1 Install digital Transmission Range (TR) sensor. 2 Loosely install the bolts. 2. NOTE: Make sure that the manual control lever is in the neutral position. Install the Digital Transmission Range (TR) Sensor Alignment Tool. The tool is designed to fit snug. 3. Tighten the bolts. 4. Reconnect the shift cable at the manual control lever. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W > Page 4410 5. Reconnect the connector. 6. Lower the vehicle. 7. Reconnect the battery ground cable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Tools and Equipment > 4R70W Special Tool Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Tools and Equipment > 4R70W > Page 4413 Special Tool Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications Vehicle Speed Sensor: Specifications Vehicle Speed Sensor Bolt 11-13 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4419 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4420 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4421 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4422 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4423 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4424 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4425 Vehicle Speed Sensor: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4426 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4427 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4428 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4429 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4430 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4431 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Exhaust System - Catalytic Converter Ticking/Knocking Catalytic Converter: Technical Service Bulletins Exhaust System - Catalytic Converter Ticking/Knocking TSB 04-20-6 10/18/04 TICKING OR KNOCKING NOISE COMING FROM THE CATALYTIC CONVERTERS FORD: 1997-1998 F-250 LD 1997-2003 F-150 ISSUE Some 1997-2003 F-150 vehicles equipped with any engine, and 1997-1998 F-250 LD vehicles equipped with the 5.4L engine, may exhibit a ticking or knocking noise coming from the catalytic converters. The noise may be described as sounding like a diesel engine. The condition will be present when the vehicle is in gear at idle only, and is more pronounced when the vehicle is stationary, such as sitting in a drive-through line. The noise is normal, and is created by engine pulses being amplified through the light-off converters. ACTION DO NOT replace converters unless loose internal components are found. To reduce the noise, install a wrap kit on each of the light-off converters. Refer to the instruction sheet included in the kit. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage Parts Block OPERATION DESCRIPTION TIME 042006A Install Wrap Kit On Both 0.7 Hr. Light-Off Converters (Includes Time To Perform Road Test) DEALER CODING CONDITION BASIC PART NO. CODE 5E212 42 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Exhaust System - Catalytic Converter Ticking/Knocking > Page 4437 Technical Service Bulletin # 01-9-7 Date: 010514 Emissions/Engine Controls - Driveability Diagnosis Article No. 01-9-7 05/14/01 DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA 1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS 1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR 1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150, F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS 1998-2001 NAVIGATOR MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000 MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs). Additional information is included to assist in diagnosing certain vehicle symptoms. This article is NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when diagnosing vehicle conditions. ACTION Use the following information and Service Tips to assist in the diagnosis of H025, Catalyst, and Fuel System Monitor related DTCs. OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 623000, 690000, 698298 Information ^ A. Description of Terms and Acronyms ^ B. HO2S Location Diagrams ^ C. Heated Oxygen Sensor (HO2S) Monitor Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Exhaust System - Catalytic Converter Ticking/Knocking > Page 4438 ^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information ^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs) ^ D. Catalyst Efficiency Monitor ^ D1. Catalyst Efficiency Monitor - Information ^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs) ^ E. Fuel System Monitor ^ E1. Fuel System Monitor - Information ^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs) ^ F. Diagnostic Service Tips ^ F1. Tips - General ^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor ^ F3. Tips Related to Catalyst Monitor ^ F4. Tips Related to Fuel System Monitor A. Description of Terms and Acronyms ^ CHT - Cylinder Head Temperature Sensor or PID ^ CKP - Crankshaft Position Sensor or PID ^ DTC - Diagnostic Trouble Code ^ ECT - Engine Coolant Temperature Sensor or PID ^ EGR - Exhaust Gas Recirculation ^ EEC - Electronic Engine Control ^ EVR - EGR Vacuum Regulator ^ FMEM - Failure Mode Effects Management ^ GND - Ground ^ HC - Hydrocarbons ^ HO2S - Heated Oxygen Sensor or PID ^ IAT - Inlet Air Temperature Sensor or PID ^ KAM - Keep Alive Memory ^ KOEO - Key On Engine Off ^ KOER - Key On Engine Running ^ LONGFT - Long Term Fuel Trim ^ MAF - Mass Air Flow Sensor or PID ^ MIL - Malfunction Indicator Lamp ("Check Engine") ^ NGS - New Generation Star Tester (Scan Tool) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Exhaust System - Catalytic Converter Ticking/Knocking > Page 4439 ^ OBD II - On-Board Diagnostics II ^ OSM - Output State Monitor ^ PC/ED - Powertrain Control/Emissions Diagnosis ^ PCM - Powertrain Control Module ^ PCV - Positive Crankcase Ventilation ^ PID - Parameter Identification Display ^ RAM - Random Access Memory ^ RPM - Revolutions Per Minute ^ SHRTFT - Short Term Fuel Trim ^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines) ^ TP - Throttle Position Sensor or PID ^ VMV - Vapor Management Valve ^ VPWR - Vehicle Power (Battery Voltage) ^ VREF - Vehicle Reference Voltage (5 volts) B. HO2S Location Diagrams Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing the # 1 cylinder. C. Heated Oxygen Sensor (HO2S) Monitor C1.) Heated Oxygen Sensor (HO2S) Monitor - Information Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Exhaust System - Catalytic Converter Ticking/Knocking > Page 4440 The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3) used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S Monitor is enabled. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. ^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst Monitor) HO2S for proper function. ^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. ^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage amplitude and output response frequency are observed. A sample of the upstream HO2S signal is evaluated to determine if the sensor is capable of switching or has a slow response rate. ^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a corresponding change in the OSM and by measuring the current going through the heater circuit. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The HO2S Monitor DTCs can be categorized as follows: ^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156 ^ HO2S slow response rate - P0133, P0153 ^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161 ^ Downstream HO2S not running in on-demand self test - P1127 ^ Swapped H025 connectors - P1128 and P1129 ^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152 ^ HO2S lack of switching (sensor indicates lean) - P1137 ^ H025 lack of switching (sensor indicates rich) - P1138 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Exhaust System - Catalytic Converter Ticking/Knocking > Page 4441 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Exhaust System - Catalytic Converter Ticking/Knocking > Page 4442 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Exhaust System - Catalytic Converter Ticking/Knocking > Page 4443 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Exhaust System - Catalytic Converter Ticking/Knocking > Page 4444 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Exhaust System - Catalytic Converter Ticking/Knocking > Page 4445 C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes D. Catalyst Efficiency Monitor D1.) Catalyst Efficiency Monitor - Information The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested and verified to be functional. This monitor relies on the front and rear heated oxygen sensors (HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly, approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or 0.9 for a low efficiency catalyst. Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst is monitored. Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF (greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle) are required. ^ Because an exponentially weighted moving average is used for malfunction determination, up to six OBD II drive cycles may be required to illuminate the MIL. NOTE THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES) WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE "FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST MONITOR: The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The Monitor then observes the switching frequency and compares it to a threshold frequency stored in an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a malfunction. The Catalyst Monitor DTCs can be categorized as follows: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Exhaust System - Catalytic Converter Ticking/Knocking > Page 4446 ^ Catalyst system efficiency below threshold (Bank 1) - P0420 ^ Catalyst system efficiency below threshold (Bank 2) - P0430 D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes E. Fuel System Monitor E1.) Fuel System Monitor - Information The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel system components due to normal wear and aging. Fuel trim tables are based on vehicle speed and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables. The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF sensors is required to activate the fuel trim system, which in turn activates the Fuel System Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor will store the appropriate DTC when a fault is detected as described below. ^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback indicating a rich or lean condition. ^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and Short Term Fuel Trims as needed to compensate for variations in the fuel system. ^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached adaptive limit), the Fuel System Monitor sets a DTC. ^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles. The Fuel System Monitor DTCs can be categorized as follows: ^ Fuel Delivery Error - P0148 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Exhaust System - Catalytic Converter Ticking/Knocking > Page 4447 ^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2) ^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Exhaust System - Catalytic Converter Ticking/Knocking > Page 4448 E2.) Fuel System Monitor - Diagnostic Trouble Codes F. Diagnostic Service Tips 1. Always reset KAM after performing a repair: After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM. When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the PCM will be able to start with "base tables". 2. Always view and record Freeze Frame Data: Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in which the vehicle was being driven at the time the fault occurred. This can be especially useful on intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data. 3. Multiple DTCs (with the same meaning): When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue that is causing the codes. Examples of multiple (paired) DTCs: (P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152). To further clarify this, see the more detailed scenario as follows: A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155 (HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of these DTCs would be something in the heater power circuit that both of these HO2S sensors have in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered, reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When reviewing the wiring diagram, look for things that the affected sensors have in common. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Exhaust System - Catalytic Converter Ticking/Knocking > Page 4449 In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present) would be a concern with Splice "B" (refer to Figure 2). NOTE THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE CIRCUITS SHOWN. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Exhaust System - Catalytic Converter Ticking/Knocking > Page 4450 4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4). In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts. 5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned fuel. Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to the amount of unburned fuel in the exhaust system. However, there is also a large amount of unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses oxygen only, it would report a lean condition in this particular situation. F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor 1. OBD II Response Rate Monitor: The OBD II Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95 km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds. Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay. 2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow, throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving habits, engine and component wear, etc.). F3.) Tips Related to Catalyst Efficiency Monitor 1. Determining catalyst efficiency/switch ratio: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Exhaust System - Catalytic Converter Ticking/Knocking > Page 4451 The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The switch ratio is determined by dividing the number of downstream switches by the number of upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged or contaminated), the downstream switches will increase. When the downstream switch rate crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430) and the MIL illuminates (refer to Figures 5 and 6). NOTE IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE NECESSARY. 2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the handling of H025 sensors to prevent damage or contamination. Do not use power tools in the removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025 sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft). 3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430: When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service Manual. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Exhaust System - Catalytic Converter Ticking/Knocking > Page 4452 F4.) Tips Related to the Fuel System Monitor 1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175: Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally. Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED Service Manual. 2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern, then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual. 3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There are different types of lean conditions. The ability to identify the type of lean condition causing the concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present, there is a strong likelihood of another concern being present: a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by air entering the engine through an abnormal source (opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is cold might be the best starting point. Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings, throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated engine oil dipstick, MAF reading lower than normal, etc. b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This condition is typically caused by a fuel delivery system concern that restricts or limits the amount of fuel being delivered to the engine. This condition will normally be most apparent when the engine is under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure with engine under a load) might be the best starting point. Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel injector concerns, etc. c. Exhaust system leaks: In this type of condition, the engine may actually be running near stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is caused by oxygen-rich air entering the exhaust system through an external source. This condition will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine may not be. Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection system d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10. 4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent or kinked lines, degraded fuel pump). At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is needed to maintain the correct fuel pressure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 4453 Catalytic Converter: Specifications Three Way Catalytic Converter to Exhaust Manifold Nuts 34-46 Nm Exhaust Converter Frame Bracket to Catalytic Converter Pipe Nuts 34-46 Nm LH to RH Catalytic Converter Pipe Clamp Nuts 47-63 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 4454 Catalytic Converter: Service and Repair Removal 1. Remove the muffler and tail pipe assembly. 2. NOTE: On the 4.2L engine, the two upstream Heated Oxygen Sensors (H02S) are located on the exhaust manifolds and do not need to be removed. Disconnect the H02S and the catalyst monitor sensor. 3. Remove the nuts. 4. Remove the transfer case skid plate, if equipped. 1 Remove the bolts. 2 Remove the transfer case skid plate. 5. Remove the two bolts retaining the heat shield to the transmission support crossmember bolts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 4455 6. Use a High-Lift jack to support the transmission. 7. Remove the nuts. 8. Remove the transmission support crossmember. 1 Remove the bolts. 2 Remove the transmission support crossmember. 9. On 4.2L or 4.6L engine, remove the nuts. 10. On 5AL engine, remove the nuts. 11. Remove the two TWCs. 1 For 4.2L or 4.6L engine, perform Steps 12 and 13. 2 For 5.4L engine, perform Steps 14 and 15. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 4456 12. On 4.2L and 4.6L engine, if only one TWC is being replaced, remove the LH to RH TWC clamp. 13. NOTE: It may be necessary to heat the LH to RH three way catalytic converter joint to ease removal. Separate the LH and RH TWCs. 14. On 5.4L, engine, if only one TWC is being replaced, remove the clamp. 15. NOTE: It may be necessary to heat the LH to RH three way catalytic converter joint to ease removal. Separate the LH and RH TWCs. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 4457 1. Insert the LH TWC into the RH TWC. 2. On 5AL engine, insert the LH TWC into the RH TWC. 3. On 5.4L engine, install the pipe clamp. - Install the nuts. 4. Position the RH and LH TWCs and install the nuts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 4458 5. Install the LH to RH three way catalytic converter pipe clamp. - Install the two nuts. - The 4.2L and 4.6L, components are shown; the 5.4L system is similar. 6. On 4.2L and 4.6L engine, install the nuts. 7. On 5.4L engine, install the nuts. 8. Install the transmission support crossmember. 1 Position the transmission support crossmember. 2 Install the bolts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Technical Service Bulletins > Page 4459 9. Install the nuts. 10. Install the heat shield to crossmember bolts. 11. Remove the High-Lift Jack. 12. Connect the heated oxygen sensor and the two catalyst monitor sensor electrical connectors. 13. Install the transfer case skid plate. 1 Position the transfer case skid plate. 2 Install the bolts. 14. Install the muffler and tailpipe. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Service and Repair Canister Purge Control Valve: Service and Repair REMOVAL WARNING: THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Disconnect the electrical connector from the Evaporative Emission (EVAP) canister purge valve and the evaporative emissions vacuum control hose. 2. Disconnect the two fuel vapor tubes. 1 Disconnect the EVAP canister purge outlet tube. 2 Disconnect the evaporative emission return tube. 3. Remove the evaporative emission canister purge valve. 1 Remove the bolts. 2 Remove the evaporative emission canister purge valve. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Service and Repair > Page 4464 1. To install, reverse the removal procedure. 2. Leak test the system. 3. Carry out the Evaporative Emission Running Loss Monitor Repair Verification Drive Cycle Test. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Service and Repair Canister Purge Solenoid: Service and Repair REMOVAL WARNING: THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Raise and support the vehicle. 2. Disconnect the canister vent solenoid electrical connector. 3. Remove the bolts. 4. Remove the bolts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Service and Repair > Page 4468 5. Disconnect the canister vent solenoid hose assembly. ^ Reposition the canister and bracket. ^ Disconnect the hose. 6. Remove the canister vent solenoid. INSTALLATION 1. To install, reverse the removal procedure. 2. Leak Test the system. 3. Carry out the Evaporative Emission Running Loss Monitor Repair Verification Drive Cycle Test. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications Evaporative Emission Control Canister: Specifications Evaporative emission canister purge valve bolts 10 Nm Evaporative emission canister bracket bolts 25 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications > Page 4472 Evaporative Emission Control Canister: Service and Repair REMOVAL WARNING: THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Raise and support the vehicle. 2. Disconnect the canister vent solenoid electrical connector. 3. Remove the bolts. 4. Remove the bolts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications > Page 4473 5. Disconnect the canister vent solenoid hose assembly. ^ Lower the canister and bracket. ^ Disconnect the hose. 6. Disconnect the Evaporative Emissions (EVAP) canister purge outlet tube. ^ Reposition the clamp. ^ Disconnect the tube. 7. Remove the canister vent solenoid. 8. Remove the evaporative emissions canister INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Component Information > Specifications > Page 4474 1. To install, reverse the removal procedure. NOTE: Lubricate all O-rings with Merpol (R) or equivalent meeting Ford specification ESE-M99B144-B before installation. 2. Leak test the system. 3. Carry out the Evaporative Emission Running Loss Monitor Repair Verification Drive Cycle Test. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid Vapor Separator, Evaporative System > Component Information > Service and Repair Liquid Vapor Separator: Service and Repair REMOVAL 1. Remove the fuel tank. 2. Remove the fuel vapor vent valve. 1 Slide the clamp away from the evaporative emission valve and remove the evaporative emission return tube. 2 Press down and rotate the evaporative emission valve counterclockwise and remove it from the fuel tank. CAUTION: The fuel vapor vent valve must be disengaged from the fuel tank before it can be removed. Rotate the fuel vapor vent valve counterclockwise to disengage from the fuel tank. Failure to do so can cause damage to the fuel vapor vent valve or the fuel tank. INSTALLATION 1. To install, reverse the removal procedure. 2. Leak test the system. 3. Carry out the Evaporative Emission Running Loss Monitor Repair Verification Drive Cycle Test. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Specifications EGR Electronic Vacuum Regulator Solenoid: Specifications EGR Vacuum Regulator Solenoid Nuts 2.2-5.5 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Electronic Vacuum Regulator Solenoid > Component Information > Specifications > Page 4482 EGR Electronic Vacuum Regulator Solenoid: Service and Repair REMOVAL 1. Remove the EGR vacuum regulator solenoid 1 Disconnect the vacuum hose. 2 Disconnect the electrical connector. 3 Remove the nuts. 4 Remove the EGR vacuum regulator solenoid INSTALLATION 4.6L engine is shown; 5.4L engine is similar 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair EGR Tube: Service and Repair REMOVAL 1. Remove the EGR valve to exhaust manifold tube. ^ Disconnect the upper and lower EGR valve to exhaust manifold tube fittings. ^ Disconnect the two differential pressure feedback EGR hoses. INSTALLATION 1. Connect the EGR valve to exhaust manifold tube upper fitting. ^ Tighten both fittings starting at the top in two steps. ^ Hand tighten. ^ Tighten to 55-65 N.m (41-47 Lb/Ft). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications EGR Valve: Specifications Brake Booster Tube Bracket Nut 10 Nm EGR Valve Bolts 8-11 Nm EGR Valve Tube at Valve 40 Nm EGR Valve to Exhaust Manifold Tube Fittings 55-65 Nm EGR Valve Adapter Bolts 8-11.5 Nm EGR Valve Adapter Nut 8-11.5 Nm EGR Valve Tube Nut 34-47 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 4489 EGR Valve: Service and Repair REMOVAL 1. Disconnect the EGR valve vacuum hose 2. Remove the differential pressure feedback EGR sensor nuts and place the differential pressure feedback EGR sensor transducer to the side. 3. Disconnect the EGR valve to exhaust manifold tube upper fitting. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 4490 4. Remove the two bolts and the EGR valve gasket. Discard the gasket. INSTALLATION 1. Follow the removal procedure in reverse order. NOTE: Install a new EGR gasket. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 4491 2. Connect the EGR valve to exhaust manifold tube upper fitting. ^ Tighten both fittings starting at the top in two steps. Hand tighten. - Tighten to 55-65 N.m (41-47 Lb/Ft). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications Pressure Feedback Exhaust Sensor: Specifications Differential Pressure Feedback EGR Sensor Nuts 8-12 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 4495 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Remove the differential pressure feedback EGR sensor. 1 Remove the differential pressure feedback EGR sensor tubes. 2 Disconnect the differential pressure feedback EGR sensor electrical connector. 3 Remove the two nuts. 4 Remove the differential pressure feedback EGR sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Component Information > Description and Operation Positive Crankcase Ventilation: Description and Operation PCV System Flow Schematic Typical PCV Valve Typical PCV Vacuum Connector The Positive Crankcase Ventilation (PCV) System cycles crankcase gases back through the engine where they are burned. The PCV valve regulates the amount of ventilating air and blow-by gas to the intake manifold and prevents backfire from traveling into the crankcase. The PCV valve should be mounted in a vertical position. On some applications, the PCV system is connected to the evaporative emission system (refer to the VECI decal). CAUTION: Do not remove the PCV system from the engine. Removal of the PCV system will adversely affect the fuel economy and engine ventilation and result in shorter engine life. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications Pressure Feedback Exhaust Sensor: Specifications Differential Pressure Feedback EGR Sensor Nuts 8-12 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Specifications > Page 4503 Pressure Feedback Exhaust Sensor: Service and Repair REMOVAL 1. Remove the differential pressure feedback EGR sensor. 1 Remove the differential pressure feedback EGR sensor tubes. 2 Disconnect the differential pressure feedback EGR sensor electrical connector. 3 Remove the two nuts. 4 Remove the differential pressure feedback EGR sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications Fuel Pressure Test Port: Specifications Fuel pressure relief valve 8 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 4509 Fuel Pressure Test Port: Service and Repair REMOVAL WARNING ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Release fuel pressure. 2. Remove the pressure relief valve. INSTALLATION 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Gauge Special Tool(s) WARNING - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the Schrader valve cap and install the Fuel Pressure Gauge. 2. Open the manual valve slowly on the Fuel Pressure Gauge and relieve the fuel pressure. - This will drain some fuel out of the system. Place the fuel in a suitable container. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > With 4R70W Idle Speed: Specifications With 4R70W Hot Idle ................................................................................................................................................ .................................................................. 720 RPM Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications > With 4R70W > Page 4517 Idle Speed: Specifications With 4R100 Hot Idle ................................................................................................................................................ ......................................................... 760 - 830 RPM Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Alternative Fuel Control Module > Component Information > Technical Service Bulletins > Bi-Fuel System - Compuvalve Replacement Alternative Fuel Control Module: Technical Service Bulletins Bi-Fuel System - Compuvalve Replacement Article No. 01-10-6 05/28/01 DRIVEABLITY - BI-FUEL - COMPUVALVE PRE-REPLACEMENT CHECK LIST - SERVICE TIPS FORD: 1996-2000 CONTOUR 1994-2001 F-150, F-250 LD 1995-2001 E-250, E-350 1999-2001 SUPER DUTY F SERIES ISSUE This article will be used as an aid in diagnosis to avoid unnecessary replacement of the compuvalve on bi-fuel vehicles after normal diagnosis has determined the compuvalve may be faulty. ACTION Complete the normal diagnostic methods and pinpoint tests. Should the conclusion be after normal diagnosis to replace the compuvalve, then follow the compuvalve Pre-Replacement Checklist (below) before replacing the compuvalve. SERVICE INFORMATION Glossary Of Terms ^ ALT - Alternate Fuel Mode ^ FAP - Fuel Absolute Pressure ^ HPS - High Pressure Solenoid ^ VCL - Vehicle Communications Link ^ AFCM - Alternate Fuel Control Module ^ WDS - Worldwide Diagnostic System ^ DTC - Diagnostic Trouble Code ^ MAP - Manifold Absolute Pressure ^ LPG - Liquid Propane Gas ^ EEC - Electronic Engine Control NOTE THE FOLLOWING IS A LIST OF KNOWN MIS-DIAGNOSIS OF THE COMPUVALVE REPLACEMENT ON BI-FUEL VEHICLES. 1. MAP line loose. 2. High FAP from vaporizer breakdown. 3. Incorrect interpretation of DTCs. 4. VCL replacement due to harness faults. 5. Misfire due to leaking 0-rings. 6. Compuvalve replaced without checking HPS circuit for correct resistance. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Alternative Fuel Control Module > Component Information > Technical Service Bulletins > Bi-Fuel System - Compuvalve Replacement > Page 4522 7. Low FAP due to lockoff fault. 8. LPG fuel filter in backward. COMPUVALVE PRE-REPLACEMENT CHECKLIST 1. Check communication ability with EEC, AFCM/compuvalve and VCL and compuvalve. Follow the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual procedures for the appropriate vehicle. 2. Check MAP line. Follow normal diagnostic methods and visual checks. 3. Check harness and connection integrity. Follow normal diagnostic methods, basic circuit checks and harness connections. 4. Check current bi-fuel EEC calibration code. Refer to WDS. 5. Check fuel gauge with fuel selector switch in ALT position for fuel level. 6. Check power to compuvalve. Power to the compuvalve is indicated by the following fuel selector switch light status: On steady = OK, On then Off or Flashing (regular and irregular) indicated fault. 7. Check that the arrow on the LPG fuel filter is pointing in the direction of fuel flow. 8. Check base vehicle. Run vehicle in gas mode (e.g., borderline secondary ignition). Follow normal diagnostic methods. 9. Check other applicable TSBs and special service messages. 10. Verify ALT fuel switch status. Refer to Section 1 of the appropriate PC/ED Workshop Manual. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 490000, 602300, 603300, 608000, 609000, 611000, 623000, 690000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications Accelerator Pedal: Specifications Accelerator Pedal and Shaft Bolts 10 Nm Accelerator Control Splash Shield Bolts 6 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Specifications > Page 4526 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Testing and Inspection > Flow of Diagnosis Accelerator Pedal: Flow of Diagnosis 1. Verify the customer's concern by operating the acceleration control system to duplicate the condition. 2. Inspect to determine if any of the following mechanical concerns apply. VISUAL INSPECTION CHART Mechanical ^ Damaged accelerator pedal and shaft. ^ Damaged linkage. ^ Damaged accelerator cable. ^ High engine idle speed. ^ Damaged throttle body. 3. If the inspection reveals an obvious concern that can be readily identified, repair it as required. 4. If the concern remains after the inspection, determine the symptom(s) and go to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4529 Accelerator Pedal: Initial Inspection and Diagnostic Overview 1. Verify the customer's concern by operating the acceleration control system to duplicate the condition. 2. Inspect to determine if any of the following mechanical concerns apply. VISUAL INSPECTION CHART Mechanical ^ Damaged accelerator pedal and shaft. ^ Damaged linkage. ^ Damaged accelerator cable. ^ High engine idle speed. ^ Damaged throttle body. 3. If the inspection reveals an obvious concern that can be readily identified, repair it as required. 4. If the concern remains after the inspection, determine the symptom(s) and go to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Testing and Inspection > Flow of Diagnosis > Page 4530 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Testing and Inspection > Page 4531 Accelerator Pedal: Service and Repair REMOVAL 1. Disconnect the accelerator cable from the accelerator pedal and shaft. 2. Remove the bolts and remove the accelerator cable. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair REMOVAL 1. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the shield. 2. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. 3. Disconnect the (A) Positive Crankcase Ventilation (PCV) hose and the (B) Idle Air Control (IAC) valve inlet tube. 4. Loosen the clamps and remove the air cleaner outlet tube and resonator. INSTALLATION 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair > Page 4536 CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. NOTE: The inlet air cleaner has an alignment tab which fits into a slot on the outlet air cleaner. Make sure the tabs are aligned correctly. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Service and Repair Air Filter Element: Service and Repair REMOVAL 1. Open the (A) air cleaner clamp and set the (B) outlet Air Cleaner (ACL) aside. 2. Remove the (A) Air Cleaner (ACL) element from the (B) open end of inlet. INSTALLATION 1. To install, reverse the removal procedure. CAUTION: The air cleaner outlet tube should be securely sealed to prevent unmetered air from entering the engine. NOTE: The inlet air cleaner has an alignment tab which fits into a slot on the outlet air cleaner. Make sure tabs are aligned correctly. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4548 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4549 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4555 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4556 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 4557 Air Flow Meter/Sensor: Specifications Mass Airflow Sensor (MAF) Plate Nuts 8-11.5 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 4558 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 4559 Air Flow Meter/Sensor: Service and Repair REMOVAL WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. THE SENSOR CAN BE DAMAGED BY TOUCHING. 1. Disconnect the battery ground cable. 2. Open the engine air cleaner. ^ Disconnect the Mass Air Flow (MAF) sensor connector from the wiring harness. ^ Release the air cleaner clamp. ^ Separate the inlet side of the air cleaner from the outlet side of the air cleaner. 3. Cut the tape on the wire loom of the extension harness. ^ Peel back the wire loom from the extension harness near the grommet in the air cleaner. CAUTION: Do not cut the MAF sensor wires when cutting the tape on the wire loom. 4. Remove the grommet from the outlet side of the air cleaner and slide the grommet down the extension harness. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 4560 5. Remove the MAF sensor plate and mass air flow sensor from the outlet side of the engine air cleaner. 6. Disconnect the MAF sensor connector. 7. Remove the nuts and separate the MAF plate from the mass air flow sensor. INSTALLATION 1. Follow the removal procedure in reverse order. CAUTION ^ Do not tamper with the MAF sensing elements located in the airflow bypass; tampering may result in unit failure. ^ The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. NOTE ^ The MAF sensor module and body are calibrated and replaced as a unit. ^ Use the alignment notch to properly align the inlet side and the outlet side of the engine air cleaner. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest: > 02-10-8 > May > 02 > Fuel System - Whistling Noise Auxiliary Air Valve (Idle Speed): Customer Interest Fuel System - Whistling Noise Article No. 02-10-8 05/27/02 ^ DRIVEABILITY - 5.4L 2V - IDLE-AIR BYPASS FLOW INDUCED WHISTLE ^ ENGINE - 5.4L 2V - IDLE-AIR BYPASS FLOW INDUCED WHISTLE ^ NOISE - IDLE-AIR BYPASS FLOW INDUCED WHISTLE - VEHICLES EQUIPPED WITH 5.4L 2V ENGINE ONLY FORD: 1999-2002 E SERIES, EXPEDITION, F-150, SUPER DUTY F SERIES ISSUE Some vehicles equipped with the 5.4L 2V engine may exhibit a "whistling" noise from the formed nylon tube in the idle-air bypass flow circuit. This may be caused by air flow passing through the sharp bend radius of the original tube assembly. ACTION Remove and replace formed nylon tube with the Nipple And Hose Assembly 2L1Z-9W548-AA. This action will correct the sharp bend in the tube. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the formed tube as shown (Figure 1). 2. Replace with Nipple And Hose Assembly with part 2L1Z-9W548-AA. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > Customer Interest: > 02-10-8 > May > 02 > Fuel System - Whistling Noise > Page 4569 3. Connect nipple to the air-inlet zip tube and the free end connects to resonator as shown (Figure 2). 4. Ensure that there are no kinks in the rubber hose which could restrict air flow. LABOR OPERATION CLAIMING CHART PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9H308 V3 OASIS CODES: 497000, 702000, 702100 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-10-8 > May > 02 > Fuel System - Whistling Noise Auxiliary Air Valve (Idle Speed): All Technical Service Bulletins Fuel System - Whistling Noise Article No. 02-10-8 05/27/02 ^ DRIVEABILITY - 5.4L 2V - IDLE-AIR BYPASS FLOW INDUCED WHISTLE ^ ENGINE - 5.4L 2V - IDLE-AIR BYPASS FLOW INDUCED WHISTLE ^ NOISE - IDLE-AIR BYPASS FLOW INDUCED WHISTLE - VEHICLES EQUIPPED WITH 5.4L 2V ENGINE ONLY FORD: 1999-2002 E SERIES, EXPEDITION, F-150, SUPER DUTY F SERIES ISSUE Some vehicles equipped with the 5.4L 2V engine may exhibit a "whistling" noise from the formed nylon tube in the idle-air bypass flow circuit. This may be caused by air flow passing through the sharp bend radius of the original tube assembly. ACTION Remove and replace formed nylon tube with the Nipple And Hose Assembly 2L1Z-9W548-AA. This action will correct the sharp bend in the tube. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the formed tube as shown (Figure 1). 2. Replace with Nipple And Hose Assembly with part 2L1Z-9W548-AA. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-10-8 > May > 02 > Fuel System - Whistling Noise > Page 4575 3. Connect nipple to the air-inlet zip tube and the free end connects to resonator as shown (Figure 2). 4. Ensure that there are no kinks in the rubber hose which could restrict air flow. LABOR OPERATION CLAIMING CHART PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9H308 V3 OASIS CODES: 497000, 702000, 702100 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Auxiliary Air Valve (Idle Speed): > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold Rocker Arm Assembly: All Technical Service Bulletins Engine - Rough Idle/Noise When Cold Article No. 00-26-1 12/25/00 ^ ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 ^ NOISE - FROM ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 FORD: 1997-1999 F-250 LD 1997-2000 ECONOLINE, EXCURSION, EXPEDITION, F-150 1999-2000 F SUPER DUTY LINCOLN: 1998-1999 NAVIGATOR ISSUE Some vehicles equipped with a 4.6L, 5.4L, or 6.8L engine may exhibit a rough idle/miss after start-up in cold ambient temperatures (less than -12°C/10 ° F). This may be caused by a roller finger follower(s) being dislodged from the valve. This may result in damage to the camshaft, roller finger follower, valve, retainer, etc. A procedure is now available to service this condition. ACTION Inspect and replace any worn or damaged engine valve components and install new retaining clip and lash adjuster for service. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform normal engine diagnostic routines before opening valve covers. If the valve train is suspect, remove the valve covers and look for Roller Finger Follower(s) (RFF) that may have become dislodged. 1. Inspect the following parts that may have been damaged by any dislodged roller finger followers: ^ Cam lobes (chipped or grooved) ^ Valve stem tips (mushroomed, metal displaced, or bent) ^ Roller finger followers (chipped or grooved) ^ Inspect valve guide only if its corresponding RFF or valve stem tip is damaged. Replace damaged parts as necessary. 2. If follower(s) are damaged, replaced as necessary, otherwise re-use followers in same location as removed from head. 3. Remove all intake and exhaust lash adjusters from the engine and replace with service-only Lash Adjusters (YL3Z-6500-AA). Refer to the appropriate workshop Manual, Section 303-01B for service procedures and tooling necessary to compress the valve springs and remove the roller followers. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Auxiliary Air Valve (Idle Speed): > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 4581 NOTE REFER TO FIGURE 1 FOR INSTALLATION OF THE NEW RETAINING CLIPS (YL3Z-6A539-AA), TO THE ROLLER FINGER FOLLOWER. 4. Using a valve spring compression tool, install followers and the attached retaining clips by pushing clips onto lash adjuster. NOTE THE CLIP IS NOT REMOVABLE FROM ADJUSTER ONCE IT HAS BEEN SNAPPED INTO PLACE. IF THE ENGINE NEEDS TO BE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Auxiliary Air Valve (Idle Speed): > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 4582 SERVICED AT A LATER DATE, REMOVE THE RFF BY BENDING UP THE CLIP. LEAVE LASH ADJUSTER IN THE ENGINE WITH THE CLIP WHILE REMOVING THE FOLLOWER. THEN REMOVE THE LASH ADJUSTER FROM THE HEAD AND SNIP/CUT THE CLIP FROM THE LASH ADJUSTER. REPLACE WITH A NEW CLIP ON FOLLOWER DURING INSTALLATION. 5. Check valve train for proper assembly and reinstall valve covers as outlined in the Workshop Manual, Section 303-01B. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 497000, 499000, 602300, 608000, 608400, 609000, 609400, 613000, 613500, 702000, 702100 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Auxiliary Air Valve (Idle Speed): > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 4588 NOTE REFER TO FIGURE 1 FOR INSTALLATION OF THE NEW RETAINING CLIPS (YL3Z-6A539-AA), TO THE ROLLER FINGER FOLLOWER. 4. Using a valve spring compression tool, install followers and the attached retaining clips by pushing clips onto lash adjuster. NOTE THE CLIP IS NOT REMOVABLE FROM ADJUSTER ONCE IT HAS BEEN SNAPPED INTO PLACE. IF THE ENGINE NEEDS TO BE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Auxiliary Air Valve (Idle Speed): > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 4589 SERVICED AT A LATER DATE, REMOVE THE RFF BY BENDING UP THE CLIP. LEAVE LASH ADJUSTER IN THE ENGINE WITH THE CLIP WHILE REMOVING THE FOLLOWER. THEN REMOVE THE LASH ADJUSTER FROM THE HEAD AND SNIP/CUT THE CLIP FROM THE LASH ADJUSTER. REPLACE WITH A NEW CLIP ON FOLLOWER DURING INSTALLATION. 5. Check valve train for proper assembly and reinstall valve covers as outlined in the Workshop Manual, Section 303-01B. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 497000, 499000, 602300, 608000, 608400, 609000, 609400, 613000, 613500, 702000, 702100 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel - Volatility Related Driveability Concerns Fuel: Technical Service Bulletins Fuel - Volatility Related Driveability Concerns Article No. 98-26-2 01/04/99 FUEL - INFORMATION ON GASOLINE - TIPS TO RESOLVE VOLATILITY RELATED DRIVEABILITY CONCERNS FORD: 1985-97 THUNDERBIRD 1986-99 MUSTANG, TAURUS 1987-99 ESCORT 1988-94 TEMPO 1989-97 PROBE 1990-99 CROWN VICTORIA 1992-93 FESTIVA 1995-99 CONTOUR LINCOLN-MERCURY: 1985-97 COUGAR 1986-92 MARK VII 1986-99 SABLE 1987-89 TRACER 1988-94 TOPAZ 1988-99 CONTINENTAL 1990-99 GRAND MARQUIS, TOWN CAR 1991-99 TRACER 1993-98 MARK VIII 1995-99 MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1986-97 AEROSTAR 1987-96 BRONCO 1989-97 F SUPER DUTY, F-350 1989-99 F-150, F-250 LD, RANGER 1991-99 EXPLORER 1992-99 ECONOLINE 1993-99 VILLAGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES MEDIUM/HEAVY TRUCK: 1990-97 F-700 This TSB article is being republished in its entirety to expand vehicle model coverage and revise the text. ISSUE Some vehicles using winter blend fuels may exhibit a stall on start up and a no restart, hard start condition or a no start condition in unseasonably hot weather (greater than 27°C/80°F). These concerns may be related to fuel volatility from winter blend fuels during winter-spring and autumn-winter transitions and may result in a fuel pump vapor lock condition. This condition may appear to be a fuel pump failure but may be caused by winter blend fuel. ACTION Refer to the following text for further information. NOTE FUEL TANK ADDITIVES WILL NOT RESOLVE THESE CONCERNS BECAUSE VAPOR FORMS FROM CAVITATION WITHIN THE FUEL PUMP. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel - Volatility Related Driveability Concerns > Page 4594 FILLING THE TANK TO FULL MAY BE EFFECTIVE. ADVISE CUSTOMER TO USE THE RECOMMENDED OCTANE GRADE PER OWNER MANUAL AND NOT A HIGHER GRADE. Explain to the customer that this concern may be due to a low tank level of winter blend fuel combined with unseasonably warm weather. Advise customer that filling the fuel tank to full may be effective in resolving this concern. Also, advise customer to use the recommended octane grade per their Owner Manual and not a higher grade. BACKGROUND Gasolines are seasonally adjusted, meaning they have higher volatility (vaporize easier) in the winter and lower volatility in the summer. Government mandates to improve air quality have resulted in significant changes to gasolines, such as the mandatory use of oxygenates (ethanol, methyl tertiary butyl ether (MTBE), and others) in the winter or the reduction of Reid Vapor Pressure (RVP) in the summer. The addition of oxygenates (especially ethanol) increases volatility while the reduction of RVP reduces volatility. Gasoline distribution practices often do not allow branded marketers to have much control over their gasoline's volatility other than RVP. Oxygenate (e.g., ethanol, MTBE) use is more dependent on local gasoline markets, rather than specific marketers practice. Therefore, it is difficult to recommend specific brands to avoid volatility related complaints. OTHER APPLICABLE ARTICLES: 91-8-13 SUPERSEDES: 96-5-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES:402000, 404000, 602300, 603300, 607000, 607400, 608000, 608400, 609000, 609400, 610000, 611000, 611500, 612000, 614000, 614500, 623000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Page 4595 Fuel: Service Precautions CAUTION: Your vehicle must use unleaded fuel only. Using leaded fuel will damage the catalytic converter and affect the warranty coverage validity. CAUTION: DO NOT use gasoline containing methanol. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Cut Valve Solenoid (CNG) > Component Information > Technical Service Bulletins > Bi-Fuel - Lock Off Solenoid/Tank Valve Coil Resistance Fuel Cut Valve Solenoid (CNG): Technical Service Bulletins Bi-Fuel - Lock Off Solenoid/Tank Valve Coil Resistance Article No. 01-21-4 10/29/01 DRIVEABILITY - BI-FUEL - LOCK-OFF SOLENOID AND SOLENOID TANK VALVE COIL RESISTANCE CHART - SERVICE TIPS FORD: 1996-2000 CONTOUR 1996 E SERIES, F-150 1998-1999 E SERIES 1998-2001 F-150 1999-2001 SUPER DUTY F SERIES ISSUE This article can be used as an aid in diagnosis for clarification of lock-off solenoid and solenoid tank valve coil resistances for Bi-Fuel vehicles. ACTION Refer to the Bi-Fuel Lock-Off Solenoid And Solenoid Tank Valve Coil Resistance Chart. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Cut Valve Solenoid (LPG) > Component Information > Technical Service Bulletins > Bi-Fuel - Lock Off Solenoid/Tank Valve Coil Resistance Fuel Cut Valve Solenoid (LPG): Technical Service Bulletins Bi-Fuel - Lock Off Solenoid/Tank Valve Coil Resistance Article No. 01-21-4 10/29/01 DRIVEABILITY - BI-FUEL - LOCK-OFF SOLENOID AND SOLENOID TANK VALVE COIL RESISTANCE CHART - SERVICE TIPS FORD: 1996-2000 CONTOUR 1996 E SERIES, F-150 1998-1999 E SERIES 1998-2001 F-150 1999-2001 SUPER DUTY F SERIES ISSUE This article can be used as an aid in diagnosis for clarification of lock-off solenoid and solenoid tank valve coil resistances for Bi-Fuel vehicles. ACTION Refer to the Bi-Fuel Lock-Off Solenoid And Solenoid Tank Valve Coil Resistance Chart. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Distributor > Component Information > Technical Service Bulletins > Customer Interest for Fuel Distributor: > 00-10-4 > May > 00 > Compuvalve Rough Idle Speed/Stalls at Idle Speeds Fuel Distributor: Customer Interest Compuvalve - Rough Idle Speed/Stalls at Idle Speeds Article No. 00-10-4 05/15/00 ^ IDLE - ROUGH IDLE SPEED - BI-FUEL VEHICLES ONLY ^ STALL - DURING IDLE SPEEDS - BI-FUEL VEHICLES ONLY FORD: 1998-1999 E-250, E-350, F-150, F-250 LD ISSUE On some vehicles vaporizers with GFI model numbers Z5-1OO or Z7-1OO, may experience internal component deterioration due to fuel contamination. ACTION The following procedures are provided to expedite diagnostics and to determine if component debris (caused by fuel contamination) has impeded the operation of the Vaporizer, Compuvalve, Fuel Rails, and/or Injector Sleeves. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform all preliminary diagnostics as indicated in the Workshop Manual/Workshop information CD to ensure that the base vehicle is operational. Even a weak ignition system may cause a driveability concern in ALT fuel while not affecting gasoline. Use the NGS to verify that the PCM calibration matches the current bi-fuel calibration code in the following Calibration Chart. Confirm and record the model number of the vaporizer for the vehicle. On the F-Series truck, a mirror can be used to read the model number and on the Econoline van, unbolt the vaporizer from the bracket to read the model number. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Distributor > Component Information > Technical Service Bulletins > Customer Interest for Fuel Distributor: > 00-10-4 > May > 00 > Compuvalve Rough Idle Speed/Stalls at Idle Speeds > Page 4612 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Distributor > Component Information > Technical Service Bulletins > Customer Interest for Fuel Distributor: > 00-10-4 > May > 00 > Compuvalve Rough Idle Speed/Stalls at Idle Speeds > Page 4613 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Distributor > Component Information > Technical Service Bulletins > Customer Interest for Fuel Distributor: > 00-10-4 > May > 00 > Compuvalve Rough Idle Speed/Stalls at Idle Speeds > Page 4614 If the Vaporizer model number is not labeled Z5-1OO or Z7-1OO follow the procedures outlined in the Workshop Manual/Workshop information CD. If the Vaporizer model number is labeled Z5-1OO or Z7-1OO, continue with the following service procedure (Figures 1-3). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Distributor > Component Information > Technical Service Bulletins > Customer Interest for Fuel Distributor: > 00-10-4 > May > 00 > Compuvalve Rough Idle Speed/Stalls at Idle Speeds > Page 4615 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 603300, 607000, 607400, 608000, 608400, 609000, 609400 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Distributor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Distributor: > 00-10-4 > May > 00 > Compuvalve - Rough Idle Speed/Stalls at Idle Speeds Fuel Distributor: All Technical Service Bulletins Compuvalve - Rough Idle Speed/Stalls at Idle Speeds Article No. 00-10-4 05/15/00 ^ IDLE - ROUGH IDLE SPEED - BI-FUEL VEHICLES ONLY ^ STALL - DURING IDLE SPEEDS - BI-FUEL VEHICLES ONLY FORD: 1998-1999 E-250, E-350, F-150, F-250 LD ISSUE On some vehicles vaporizers with GFI model numbers Z5-1OO or Z7-1OO, may experience internal component deterioration due to fuel contamination. ACTION The following procedures are provided to expedite diagnostics and to determine if component debris (caused by fuel contamination) has impeded the operation of the Vaporizer, Compuvalve, Fuel Rails, and/or Injector Sleeves. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform all preliminary diagnostics as indicated in the Workshop Manual/Workshop information CD to ensure that the base vehicle is operational. Even a weak ignition system may cause a driveability concern in ALT fuel while not affecting gasoline. Use the NGS to verify that the PCM calibration matches the current bi-fuel calibration code in the following Calibration Chart. Confirm and record the model number of the vaporizer for the vehicle. On the F-Series truck, a mirror can be used to read the model number and on the Econoline van, unbolt the vaporizer from the bracket to read the model number. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Distributor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Distributor: > 00-10-4 > May > 00 > Compuvalve - Rough Idle Speed/Stalls at Idle Speeds > Page 4621 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Distributor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Distributor: > 00-10-4 > May > 00 > Compuvalve - Rough Idle Speed/Stalls at Idle Speeds > Page 4622 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Distributor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Distributor: > 00-10-4 > May > 00 > Compuvalve - Rough Idle Speed/Stalls at Idle Speeds > Page 4623 If the Vaporizer model number is not labeled Z5-1OO or Z7-1OO follow the procedures outlined in the Workshop Manual/Workshop information CD. If the Vaporizer model number is labeled Z5-1OO or Z7-1OO, continue with the following service procedure (Figures 1-3). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Distributor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Distributor: > 00-10-4 > May > 00 > Compuvalve - Rough Idle Speed/Stalls at Idle Speeds > Page 4624 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 603300, 607000, 607400, 608000, 608400, 609000, 609400 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Cap: Customer Interest Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4633 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4634 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4635 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4636 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4637 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Cap: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4643 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4644 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4645 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4646 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4647 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair Fuel Pressure Release: Service and Repair Fuel Pressure Gauge Special Tool(s) WARNING - DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. - FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Remove the Schrader valve cap and install the Fuel Pressure Gauge. 2. Open the manual valve slowly on the Fuel Pressure Gauge and relieve the fuel pressure. - This will drain some fuel out of the system. Place the fuel in a suitable container. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Diagrams Fuel Injector Wiring Harness: Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Diagrams > Page 4656 Fuel Injector Wiring Harness: Service and Repair REMOVAL WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Disconnect the battery ground cable. 2. Remove the wiring splash shield. 3. Loosen the bolts on both 42 pin fuel charging wiring electrical connectors and disconnect the connectors. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Diagrams > Page 4657 4. Disconnect the (A) 16 pin fuel charging wiring electrical connector from the (B) 16 pin engine control sensor wiring electrical connector. NOTE: The (A) 16 pin fuel charging wiring electrical connector and the (B) 16 pin engine control sensor wiring electrical connector are located behind the (C) mount. 5. Disconnect the Engine Vacuum Regulator (EVR) electrical connector. 6. Disconnect the Variable Resonance Induction System (VRIS) valve electrical connector. NOTE: The generator is removed for clarity. 7. Disconnect the RH ignition coil connections. 8. Disconnect the RH radio ignition interference capacitor electrical connector. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Diagrams > Page 4658 9. Disconnect the LH ignition coil connections. 10. Disconnect the LH radio ignition interference capacitor electrical connector. 11. Disconnect the Camshaft Position (CMP) sensor electrical connector. 12. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the accelerator control splash shield. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Diagrams > Page 4659 13. Disconnect the differential pressure feedback EGR transducer electrical connector. 14. Disconnect the Idle Air Control (IAC) valve electrical connector. 15. Disconnect the Throttle Position (TP) sensor electrical connector. 16. Disconnect the Intake Air Temperature (IAT) sensor electrical connector. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Diagrams > Page 4660 17. Disconnect the water temperature indicator sender unit electrical connector. 18. Disconnect the RH fuel injector electrical connectors. 19. Disconnect the LH fuel injector electrical connectors. 20. Raise and support the vehicle. 21. Disconnect the A/C compressor clutch electrical connector. NOTE: The A/C compressor clutch electrical connector can be reached through the wheel well. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Diagrams > Page 4661 22. Disconnect the two Heated Oxygen Sensor (H02S) electrical connectors. NOTE: The engine is removed for clarity. 23. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 24. Disconnect the oil pressure sending unit electrical connector. 25. Remove the wiring harness. INSTALLATION 1. Install the wiring harness. 2. Connect the oil pressure sending unit electrical connector. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Diagrams > Page 4662 3. Connect the crankshaft position sensor electrical connector. 4. Connect the two heated oxygen sensor electrical connectors. NOTE: The engine is removed for clarity. 5. Connect the A/C compressor clutch electrical connector. NOTE: The A/C compressor clutch electrical connector can be reached through the wheel well. 6. Raise and support the vehicle. 7. Connect the LH fuel injector electrical connectors. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Diagrams > Page 4663 8. Connect the RH fuel injector electrical connectors. 9. Connect the water temperature indicator sender unit electrical connector. 10. Connect the intake air temperature sensor electrical connector. 11. Connect the throttle position sensor electrical connector. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Diagrams > Page 4664 12. Connect the idle air control valve electrical connector. 13. Connect the differential pressure feedback EGR transducer electrical connector. 14. Install the accelerator control splash shield. 15. Connect the camshaft position sensor electrical connector. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Diagrams > Page 4665 16. Connect the LH radio ignition interference capacitor electrical connector. 17. Connect the LH ignition coil connections. 18. Connect the RH radio ignition interference capacitor electrical connector. 19. Connect the RH ignition coil connections. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Diagrams > Page 4666 20. Connect the Variable Resonance Induction System (VRIS) valve electrical connector. NOTE: The generator is removed for clarity. 21. Connect the Engine Vacuum Regulator (EVR) electrical connector. 22. Connect the (A) 16 pin fuel charging wiring electrical connector from the (B) 16 pin engine control sensor wiring electrical connector. NOTE: The (A) 16 pin fuel charging wiring electrical connector and the (B) 16 pin engine control sensor wiring electrical connector are located behind the (C) mount. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring Harness > Component Information > Diagrams > Page 4667 23. Connect the connectors and and tighten the bolts on both the 42 pin connectors. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service Precautions Fuel Line Coupler: Service Precautions WARNING ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING POSSIBLE PERSONAL INJURY OR A FIRE HAZARD. ^ THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Vapor Tube Fittings Fuel Line Coupler: Service and Repair Vapor Tube Fittings DISCONNECT WARNING: THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT IN THE AREA. 1. Disconnect the battery. 2. Disconnect the vapor tube from the fitting. 1 Squeeze the fitting. 2 Disconnect the vapor tube from the fitting. CONNECT 1. Inspect the fitting and the tube for damage. 2. Remove any dirt or obstructions. 3. Lubricate the vapor tube fittings with Merpol, or equivalent, meeting specification ESE-M99B144B-B. 4. Push the tube into the fitting until it snaps in place. 5. Pull on the connection to make sure the fitting is secure. 6. Connect the battery. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Vapor Tube Fittings > Page 4673 Fuel Line Coupler: Service and Repair Spring Lock Coupling Special Tool(s) DISCONNECT WARNING ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Release the fuel pressure. 2. Remove the fuel tube clip. 3. Install the Disconnect Tool. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Vapor Tube Fittings > Page 4674 4. Close and push the Disconnect Tool into the open side of the cage. 5. Separate the fitting. 6. Remove the Disconnect Tool. CONNECT 1. Connect the fitting. ^ Inspect and clean both the coupling ends. ^ Lubricate the O-rings with clean engine oil meeting Ford specification WSS-M2C153-F. ^ Connect the fitting. ^ Pull on the fitting to make sure it is fully engaged. ^ Install the safety clip. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Vapor Tube Fittings > Page 4675 Fuel Line Coupler: Service and Repair Push Connect Fittings Fuel Line Disconnect Set Special Tool(s) DISCONNECT WARNING ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD. 1. Release the fuel pressure. 2. Disconnect the safety clip from the male hose. 3. Install the Fuel Line Disconnect Set and push into the fitting. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Vapor Tube Fittings > Page 4676 4. Separate the fittings. ^ Inspect for damage. ^ Clean the fittings. CONNECT 1. Connect the fitting. ^ Lubricate the tube end with clean engine oil meeting Ford specification WSS-M2C153-F to ease assembly. ^ Align the tube to the fitting and push until you hear a click. 2. Pull on the fitting to make sure it is fully engaged, then install the safety clip. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Vapor Tube Fittings > Page 4677 Fuel Line Coupler: Service and Repair Hairpin-Clip Fittings DISCONNECT WARNING ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING POSSIBLE PERSONAL INJURY OR A FIRE HAZARD. CAUTION: Do not use any tools. The use of tools may cause a deformity in the clip components which may cause fuel leaks. 1. Disconnect the battery. 2. Release the fuel pressure. 3. Remove the shipping tab by bending downward. 4. Spread the hairpin clip legs and push the clip into the fitting. 5. Separate the fitting from the tube. CONNECT 1. Inspect the fitting and the tube for damage. Remove any dirt or obstructions. 2. Apply a light coat of clean engine oil meeting Ford specification WSS-M2C153-F to the male tube end. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Vapor Tube Fittings > Page 4678 3. Insert the hairpin clip into the fitting. 4. Align the tube and the fitting. 5. Insert the tube in the fitting and push together until a click is heard. 6. Pull on the connection to make sure it is fully engaged. 7. Connect the battery. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Fuel Pressure Regulator Seal > Component Information > Technical Service Bulletins > Recalls for Fuel Pressure Regulator Seal: > NHTSA98V194000 > Aug > 98 > Recall 98V194000: Fuel Pressure Regulator O-ring Leak Fuel Pressure Regulator Seal: Recalls Recall 98V194000: Fuel Pressure Regulator O-ring Leak Vehicle Description: Light duty pickup trucks. The fuel pressure regulator O-ring may have been damaged when the fuel pressure regulator was installed in the engine fuel rail . If the O-ring is damaged, fuel vapor or leakage could occur. If an ignition source is present, a fire could result. Dealers will replace the fuel pressure regulator. No owner notification is required at this time. All vehicles are still in dealer's possession. 1999 FORD TRUCK F150 1999 FORD TRUCK F250 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Fuel Pressure Regulator Seal > Component Information > Technical Service Bulletins > Recalls for Fuel Pressure Regulator Seal: > 98S21 > Aug > 98 > Recall - Fuel Pressure Regulator Seal Leakage Technical Service Bulletin # 98S21 Date: 980801 Recall - Fuel Pressure Regulator Seal Leakage 98S21 SAFETY RECALL F-Series (Under 8500 # GVW) Fuel Pressure Regulator ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Customer Notification Letter Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Fuel Pressure Regulator Seal > Component Information > Technical Service Bulletins > Recalls for Fuel Pressure Regulator Seal: > 98S21 > Aug > 98 > Recall - Fuel Pressure Regulator Seal Leakage > Page 4692 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Fuel Pressure Regulator Seal > Component Information > Technical Service Bulletins > Recalls for Fuel Pressure Regulator Seal: > 98S21 > Aug > 98 > Recall - Fuel Pressure Regulator Seal Leakage > Page 4693 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to a buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Affected vehicles on the enclosed list. Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter and schedule a service date. REGIONAL CONTACT Advise regional office if: ^ an owner cannot be contacted. ^ an owner does not make a service date. CLAIMS SUBMISSION Enter claims using DWE. See ACESII Manual, Sections 5 and 6. WARRANTY AND POLICY MANUAL See Sections 5 and 6 of the ACESII Manual. REFUNDS See Section 3-59 of the ACESII Manual. Attachment II - Labor and Parts Information LABOR ALLOWANCES Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Fuel Pressure Regulator Seal > Component Information > Technical Service Bulletins > Recalls for Fuel Pressure Regulator Seal: > 98S21 > Aug > 98 > Recall - Fuel Pressure Regulator Seal Leakage > Page 4694 PARTS REQUIREMENTS Parts will be direct shipped to dealers with affected trucks for this recall. Do Not Order Parts For This Recall; Dealerships Having VIN's of Affected Trucks Will Automatically Receive Parts Via Federal Express. Parts will be in a bubble envelope labeled 98S21. Parts will be shipped beginning August 14, 1998. DEALER PRICE For latest prices, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information AFFECTED VEHICLES: CERTAIN 1999 MODEL YEAR F-SERIES (UNDER 8500 GVW) VEHICLES BUILT AT THE NORFOLK ASSEMBLY PLANT FROM JOB #1 THROUGH AUGUST 4, 1998 EQUIPPED WITH THE 4.6L OR 5.4L GASOLINE ENGINES INSPECTION 1. Visually inspect the fuel pressure regulator for a blue or green painted dot. See Figure 1. ^ It a blue or green dot is present on regulator, no service action is required. Return vehicle to customer. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Fuel Pressure Regulator Seal > Component Information > Technical Service Bulletins > Recalls for Fuel Pressure Regulator Seal: > 98S21 > Aug > 98 > Recall - Fuel Pressure Regulator Seal Leakage > Page 4695 ^ If a blue or green dot is not present on regulator, the fuel pressure regulator must be replaced. Refer to SERVICE PROCEDURE. SERVICE PROCEDURE WARNING DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. WARNING FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. 1. Relieve fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge (T80L-9974-B). ^ Slowly open manual valve on EFI/CFI fuel pressure gauge to relieve fuel pressure. This will drain some fuel out of the system. Place the fuel in a suitable container. ^ Remove fuel pressure gauge and install schrader valve cap. 2. Disconnect vacuum line from fuel pressure regulator. See Figure 2. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Fuel Pressure Regulator Seal > Component Information > Technical Service Bulletins > Recalls for Fuel Pressure Regulator Seal: > 98S21 > Aug > 98 > Recall - Fuel Pressure Regulator Seal Leakage > Page 4696 3. Locate fuel pressure regulator snap ring. Index open end of snap ring to approximately 9 o'clock position. See Figure 3. This will aid in snap ring removal. 4. Remove fuel pressure regulator snap ring. 5. Using a Rotunda Spark Plug Wire Remover (T74P-6666-A) or equivalent, remove fuel pressure regulator. Twist and pull fuel pressure regulator to remove it from its mounting. See Figure 4. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Fuel Pressure Regulator Seal > Component Information > Technical Service Bulletins > Recalls for Fuel Pressure Regulator Seal: > 98S21 > Aug > 98 > Recall - Fuel Pressure Regulator Seal Leakage > Page 4697 6. Lubricate O-rings of new fuel pressure regulator with clean 5W-30 motor oil. 7. Install fuel pressure regulator. Slight pressure is needed to seat O-rings. 8. Install snap ring, ensuring snap ring is fully seated. 9. Connect fuel pressure regulator vacuum line. 10. Start and run engine. Check fuel pressure regulator for any leaks. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Fuel Pressure Regulator Seal > Component Information > Technical Service Bulletins > Recalls for Fuel Pressure Regulator Seal: > 98S21 > Aug > 98 > Recall - Fuel Pressure Regulator Seal Leakage > Page 4698 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Fuel Pressure Regulator Seal > Component Information > Technical Service Bulletins > Recalls for Fuel Pressure Regulator Seal: > 98S21 > Aug > 98 > Recall - Fuel Pressure Regulator Seal Leakage > Page 4699 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Fuel Pressure Regulator Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator Seal: > NHTSA98V194000 > Aug > 98 > Recall 98V194000: Fuel Pressure Regulator O-ring Leak Fuel Pressure Regulator Seal: All Technical Service Bulletins Recall 98V194000: Fuel Pressure Regulator O-ring Leak Vehicle Description: Light duty pickup trucks. The fuel pressure regulator O-ring may have been damaged when the fuel pressure regulator was installed in the engine fuel rail . If the O-ring is damaged, fuel vapor or leakage could occur. If an ignition source is present, a fire could result. Dealers will replace the fuel pressure regulator. No owner notification is required at this time. All vehicles are still in dealer's possession. 1999 FORD TRUCK F150 1999 FORD TRUCK F250 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Fuel Pressure Regulator Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator Seal: > 98S21 > Aug > 98 > Recall - Fuel Pressure Regulator Seal Leakage Technical Service Bulletin # 98S21 Date: 980801 Recall - Fuel Pressure Regulator Seal Leakage 98S21 SAFETY RECALL F-Series (Under 8500 # GVW) Fuel Pressure Regulator ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Attachment III ^ Technical Information ^ Customer Notification Letter Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Fuel Pressure Regulator Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator Seal: > 98S21 > Aug > 98 > Recall - Fuel Pressure Regulator Seal Leakage > Page 4709 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Fuel Pressure Regulator Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator Seal: > 98S21 > Aug > 98 > Recall - Fuel Pressure Regulator Seal Leakage > Page 4710 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to a buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Affected vehicles on the enclosed list. Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter and schedule a service date. REGIONAL CONTACT Advise regional office if: ^ an owner cannot be contacted. ^ an owner does not make a service date. CLAIMS SUBMISSION Enter claims using DWE. See ACESII Manual, Sections 5 and 6. WARRANTY AND POLICY MANUAL See Sections 5 and 6 of the ACESII Manual. REFUNDS See Section 3-59 of the ACESII Manual. Attachment II - Labor and Parts Information LABOR ALLOWANCES Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Fuel Pressure Regulator Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator Seal: > 98S21 > Aug > 98 > Recall - Fuel Pressure Regulator Seal Leakage > Page 4711 PARTS REQUIREMENTS Parts will be direct shipped to dealers with affected trucks for this recall. Do Not Order Parts For This Recall; Dealerships Having VIN's of Affected Trucks Will Automatically Receive Parts Via Federal Express. Parts will be in a bubble envelope labeled 98S21. Parts will be shipped beginning August 14, 1998. DEALER PRICE For latest prices, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information AFFECTED VEHICLES: CERTAIN 1999 MODEL YEAR F-SERIES (UNDER 8500 GVW) VEHICLES BUILT AT THE NORFOLK ASSEMBLY PLANT FROM JOB #1 THROUGH AUGUST 4, 1998 EQUIPPED WITH THE 4.6L OR 5.4L GASOLINE ENGINES INSPECTION 1. Visually inspect the fuel pressure regulator for a blue or green painted dot. See Figure 1. ^ It a blue or green dot is present on regulator, no service action is required. Return vehicle to customer. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Fuel Pressure Regulator Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator Seal: > 98S21 > Aug > 98 > Recall - Fuel Pressure Regulator Seal Leakage > Page 4712 ^ If a blue or green dot is not present on regulator, the fuel pressure regulator must be replaced. Refer to SERVICE PROCEDURE. SERVICE PROCEDURE WARNING DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY. WARNING FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. 1. Relieve fuel system pressure as follows: ^ Remove schrader valve cap and attach EFI/CFI fuel pressure gauge (T80L-9974-B). ^ Slowly open manual valve on EFI/CFI fuel pressure gauge to relieve fuel pressure. This will drain some fuel out of the system. Place the fuel in a suitable container. ^ Remove fuel pressure gauge and install schrader valve cap. 2. Disconnect vacuum line from fuel pressure regulator. See Figure 2. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Fuel Pressure Regulator Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator Seal: > 98S21 > Aug > 98 > Recall - Fuel Pressure Regulator Seal Leakage > Page 4713 3. Locate fuel pressure regulator snap ring. Index open end of snap ring to approximately 9 o'clock position. See Figure 3. This will aid in snap ring removal. 4. Remove fuel pressure regulator snap ring. 5. Using a Rotunda Spark Plug Wire Remover (T74P-6666-A) or equivalent, remove fuel pressure regulator. Twist and pull fuel pressure regulator to remove it from its mounting. See Figure 4. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Fuel Pressure Regulator Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator Seal: > 98S21 > Aug > 98 > Recall - Fuel Pressure Regulator Seal Leakage > Page 4714 6. Lubricate O-rings of new fuel pressure regulator with clean 5W-30 motor oil. 7. Install fuel pressure regulator. Slight pressure is needed to seat O-rings. 8. Install snap ring, ensuring snap ring is fully seated. 9. Connect fuel pressure regulator vacuum line. 10. Start and run engine. Check fuel pressure regulator for any leaks. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Fuel Pressure Regulator Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator Seal: > 98S21 > Aug > 98 > Recall - Fuel Pressure Regulator Seal Leakage > Page 4715 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Fuel Pressure Regulator Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pressure Regulator Seal: > 98S21 > Aug > 98 > Recall - Fuel Pressure Regulator Seal Leakage > Page 4716 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Specifications Fuel Pressure Test Port: Specifications Fuel pressure relief valve 8 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port > Component Information > Specifications > Page 4720 Fuel Pressure Test Port: Service and Repair REMOVAL WARNING ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Release fuel pressure. 2. Remove the pressure relief valve. INSTALLATION 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications Fuel Pressure Test Port: Specifications Fuel pressure relief valve 8 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel Pressure Test Port > Component Information > Specifications > Page 4726 Fuel Pressure Test Port: Service and Repair REMOVAL WARNING ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Release fuel pressure. 2. Remove the pressure relief valve. INSTALLATION 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 4730 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Locations > Page 4731 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4734 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4735 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4736 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4737 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4738 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4739 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4740 Fuel Pump Relay: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4741 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4742 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4743 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4744 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4745 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4746 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Page 4747 Fuel Pump Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Page 4748 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Customer Interest for Fuel Rail: > 00-10-4 > May > 00 > Compuvalve - Rough Idle Speed/Stalls at Idle Speeds Fuel Rail: Customer Interest Compuvalve - Rough Idle Speed/Stalls at Idle Speeds Article No. 00-10-4 05/15/00 ^ IDLE - ROUGH IDLE SPEED - BI-FUEL VEHICLES ONLY ^ STALL - DURING IDLE SPEEDS - BI-FUEL VEHICLES ONLY FORD: 1998-1999 E-250, E-350, F-150, F-250 LD ISSUE On some vehicles vaporizers with GFI model numbers Z5-1OO or Z7-1OO, may experience internal component deterioration due to fuel contamination. ACTION The following procedures are provided to expedite diagnostics and to determine if component debris (caused by fuel contamination) has impeded the operation of the Vaporizer, Compuvalve, Fuel Rails, and/or Injector Sleeves. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform all preliminary diagnostics as indicated in the Workshop Manual/Workshop information CD to ensure that the base vehicle is operational. Even a weak ignition system may cause a driveability concern in ALT fuel while not affecting gasoline. Use the NGS to verify that the PCM calibration matches the current bi-fuel calibration code in the following Calibration Chart. Confirm and record the model number of the vaporizer for the vehicle. On the F-Series truck, a mirror can be used to read the model number and on the Econoline van, unbolt the vaporizer from the bracket to read the model number. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Customer Interest for Fuel Rail: > 00-10-4 > May > 00 > Compuvalve - Rough Idle Speed/Stalls at Idle Speeds > Page 4757 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Customer Interest for Fuel Rail: > 00-10-4 > May > 00 > Compuvalve - Rough Idle Speed/Stalls at Idle Speeds > Page 4758 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Customer Interest for Fuel Rail: > 00-10-4 > May > 00 > Compuvalve - Rough Idle Speed/Stalls at Idle Speeds > Page 4759 If the Vaporizer model number is not labeled Z5-1OO or Z7-1OO follow the procedures outlined in the Workshop Manual/Workshop information CD. If the Vaporizer model number is labeled Z5-1OO or Z7-1OO, continue with the following service procedure (Figures 1-3). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Customer Interest for Fuel Rail: > 00-10-4 > May > 00 > Compuvalve - Rough Idle Speed/Stalls at Idle Speeds > Page 4760 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 603300, 607000, 607400, 608000, 608400, 609000, 609400 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 00-10-4 > May > 00 > Compuvalve - Rough Idle Speed/Stalls at Idle Speeds Fuel Rail: All Technical Service Bulletins Compuvalve - Rough Idle Speed/Stalls at Idle Speeds Article No. 00-10-4 05/15/00 ^ IDLE - ROUGH IDLE SPEED - BI-FUEL VEHICLES ONLY ^ STALL - DURING IDLE SPEEDS - BI-FUEL VEHICLES ONLY FORD: 1998-1999 E-250, E-350, F-150, F-250 LD ISSUE On some vehicles vaporizers with GFI model numbers Z5-1OO or Z7-1OO, may experience internal component deterioration due to fuel contamination. ACTION The following procedures are provided to expedite diagnostics and to determine if component debris (caused by fuel contamination) has impeded the operation of the Vaporizer, Compuvalve, Fuel Rails, and/or Injector Sleeves. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform all preliminary diagnostics as indicated in the Workshop Manual/Workshop information CD to ensure that the base vehicle is operational. Even a weak ignition system may cause a driveability concern in ALT fuel while not affecting gasoline. Use the NGS to verify that the PCM calibration matches the current bi-fuel calibration code in the following Calibration Chart. Confirm and record the model number of the vaporizer for the vehicle. On the F-Series truck, a mirror can be used to read the model number and on the Econoline van, unbolt the vaporizer from the bracket to read the model number. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 00-10-4 > May > 00 > Compuvalve - Rough Idle Speed/Stalls at Idle Speeds > Page 4766 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 00-10-4 > May > 00 > Compuvalve - Rough Idle Speed/Stalls at Idle Speeds > Page 4767 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 00-10-4 > May > 00 > Compuvalve - Rough Idle Speed/Stalls at Idle Speeds > Page 4768 If the Vaporizer model number is not labeled Z5-1OO or Z7-1OO follow the procedures outlined in the Workshop Manual/Workshop information CD. If the Vaporizer model number is labeled Z5-1OO or Z7-1OO, continue with the following service procedure (Figures 1-3). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 00-10-4 > May > 00 > Compuvalve - Rough Idle Speed/Stalls at Idle Speeds > Page 4769 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 603300, 607000, 607400, 608000, 608400, 609000, 609400 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 4770 Fuel Rail: Specifications Fue Injection Supply Manifold Bolts 10 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 4771 Fuel Rail: Description and Operation The fuel injection supply manifold: ^ delivers fuel to the individual fuel injectors. ^ receives fuel from the fuel supply line. ^ returns unused fuel to the fuel tank through the fuel return line. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 4772 Fuel Rail: Service and Repair REMOVAL WARNING ^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. ^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Release the fuel pressure. 2. Partially drain the cooling system. 3. Remove the power steering reservoir bracket. 1 Remove the bolts. 2 Remove the power steering reservoir bracket. 4. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the accelerator control splash shield. 5. Disconnect the fuel pressure regulator valve vacuum hose. 6. Disconnect the fuel lines. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 4773 7. Disconnect the RH fuel injector electrical connectors. 8. Disconnect the LH fuel injector electrical connectors. 9. Disconnect the water heater inlet tube hose. 1 Release and move the hose clamp. 2 Disconnect the water heater inlet tube hose and position aside. 10. Remove the brake booster bracket and tube. 1 Remove the nut. 2 Release and move the two hose clamps. 3 Remove the brake booster tube. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 4774 11. Remove the Positive Crankcase Ventilation (PCV) hose. 12. Disconnect the Exhaust Gas Recirculation (EGR) valve to exhaust manifold tube. 1 Disconnect the two differential pressure feedback EGR transducer hoses. 2 Remove the EGR valve to exhaust manifold tube upper fitting. 3 Remove the EGR valve to exhaust manifold tube lower fitting. 13. Disconnect the EGR valve vacuum hose. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 4775 14. Disconnect the PCV bypass hose. 15. Disconnect the Idle Air Control (IAC) valve electrical connector. 16. Disconnect the differential pressure feedback EGR transducer electrical connector. 17. Disconnect the Vapor Management Valve (VMV) hose. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 4776 18. Disconnect the vacuum hose from the RH upper intake manifold. 19. Disconnect the RH radio ignition interference capacitor electrical connector. 20. Disconnect the LH radio ignition interference capacitor electrical connector. 21. Remove the four bolts and remove the fuel injection supply manifold. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 4777 22. Remove the fuel injectors from the fuel supply manifold. 23. Inspect the two O-rings from each fuel injector. Install new O-rings if necessary. INSTALLATION 1. Lubricate the new O-rings with clean engine oil XO-10W30-QSP or DSP or equivalent meeting Ford specification WSS-M2C153-G to aid installation. CAUTION: Use O-rings that are made of special fuel resistant material. Use of ordinary O-rings can cause the fuel system to leak. 2. Install the fuel injectors in the fuel supply manifold. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 4778 3. Install the fuel injector supply manifold and tighten the four bolts. 4. Connect the LH radio ignition interference capacitor electrical connector. 5. Connect the RH radio ignition interference capacitor electrical connector. 6. Connect the vacuum hose from the RH upper intake manifold. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 4779 7. Connect the vapor management valve hose. 8. Connect the differential pressure feedback (EGR) transducer electrical connector. 9. Connect the idle air control valve electrical connector. 10. Connect the PCV bypass hose. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 4780 11. Connect the EGR valve vacuum hose. 12. Connect the Exhaust Gas Recirculation (EGR) valve to exhaust manifold tube. 1 Install the EGR valve to exhaust manifold tube upper fitting. 2 Install the FOR valve to exhaust manifold tube lower fitting. 3 Connect the two differential pressure feed EGR transducer hoses. 13. Install the positive crankcase ventilation hose. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 4781 14. Install the brake booster bracket and tube. 1 Install the brake booster tube. 2 Compress and install the two hose clamps. 3 Install the brake booster bracket nut. 15. Connect the water heater inlet tube hose. 1 Connect the water heater inlet tube hose. 2 Compress and install the hose clamp. 16. Connect the LH fuel injector electrical connectors. 17. Connect the RH fuel injector electrical connector. 18. Connect the fuel lines. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Technical Service Bulletins > Page 4782 19. Connect the fuel pressure regulator valve vacuum hose. 20. Install the bolts. 21. Install the power steering reservoir bracket. 22. Fill the cooling system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Tools and Equipment Fuel Supply Line: Tools and Equipment 3/8" Fuel Line Remover AST tool# 8013 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Tools and Equipment > Page 4786 Used for removing 3/8" fuel lines and feed lines from the fuel pump-sending unit. - For R and R of Fuel and Feed Lines - Quick line removal - Gold-Anodized Aluminum Construction - See Application Chart - Included in the 8100, 8107 and #8110 Line Disconnect Sets. Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 This Tool is also available in the following kits: 8110 - 10-Pc. Line Disconnect Set Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Tools and Equipment > Page 4787 8107 - 7-Piece Line Disconnect Set Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Hose: Customer Interest Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4797 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4798 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4799 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4800 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4801 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Hose: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4807 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4808 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4809 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4810 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4811 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Page 4812 Fuel Filler Hose: Specifications Fuel Tank Filler Pipe Screws 1.6-2.2 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Page 4813 Fuel Filler Hose: Service and Repair REMOVAL 1. Remove fuel tank filler cap. 2. Remove the screws. 3. Remove one hose clamp on the fuel tank filler pipe support. 4. Disconnect the fuel tank filler pipe hose from the fuel tank. 5. Remove the fuel filler vent hose from fuel tank. 6. Remove the fuel tank filler pipe. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Technical Service Bulletins > Page 4814 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Neck: Customer Interest Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4823 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4824 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4825 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4826 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4827 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Neck: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4833 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4834 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4835 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4836 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 4837 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Service and Repair Fuel Tank Mounting Straps: Service and Repair REMOVAL 1. Raise and support the vehicle. 2. Remove fuel tank skid plate. 1 Remove the bolts. 2 Lower the fuel tank skid plate. 3. Position a Hi-Lift Jack under the fuel tank. 4. Remove the fuel tank support straps. 1 Remove the bolts. 2 Remove the fuel tank support straps. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Mounting Straps > Component Information > Service and Repair > Page 4841 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications Idle Speed/Throttle Actuator - Electronic: Specifications Idle Air Control (IAC) Valve Screws 8-10 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 4845 Idle Speed/Throttle Actuator - Electronic: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the shield. 3. Remove the idle air control valve. 1 Disconnect the electrical connector. 2 Disconnect the throttle bypass hose. 3 Remove the bolts. 4 Remove the IAC valve. 5 Remove and discard the IAC valve gasket. INSTALLATION 1. Install the idle air control valve. 1 Position the IAC valve and gasket. 2 Install the bolts in two stages: 8-10 N.m (71-89 Lb/In) - Tighten them an additional 85-95 degrees. NOTE: A new IAC valve gasket must be installed. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications > Page 4846 2. Connect the throttle bypass hose and the IAC electrical connector. 3. Install the accelerator control splash shield. 4. Connect the battery ground cable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Specifications Inertia Fuel Shutoff Switch: Specifications Intertia Fuel Shutoff Switch Bolts .............................................................................................................................................. 1.6-2.2 N.m (14.2-19 Lb-In) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4853 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay Main Relay (Computer/Fuel System): Testing and Inspection PCM Power Relay Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay > Page 4856 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Alternative Fuel Control Module > Component Information > Technical Service Bulletins > Bi-Fuel System - Compuvalve Replacement Alternative Fuel Control Module: Technical Service Bulletins Bi-Fuel System - Compuvalve Replacement Article No. 01-10-6 05/28/01 DRIVEABLITY - BI-FUEL - COMPUVALVE PRE-REPLACEMENT CHECK LIST - SERVICE TIPS FORD: 1996-2000 CONTOUR 1994-2001 F-150, F-250 LD 1995-2001 E-250, E-350 1999-2001 SUPER DUTY F SERIES ISSUE This article will be used as an aid in diagnosis to avoid unnecessary replacement of the compuvalve on bi-fuel vehicles after normal diagnosis has determined the compuvalve may be faulty. ACTION Complete the normal diagnostic methods and pinpoint tests. Should the conclusion be after normal diagnosis to replace the compuvalve, then follow the compuvalve Pre-Replacement Checklist (below) before replacing the compuvalve. SERVICE INFORMATION Glossary Of Terms ^ ALT - Alternate Fuel Mode ^ FAP - Fuel Absolute Pressure ^ HPS - High Pressure Solenoid ^ VCL - Vehicle Communications Link ^ AFCM - Alternate Fuel Control Module ^ WDS - Worldwide Diagnostic System ^ DTC - Diagnostic Trouble Code ^ MAP - Manifold Absolute Pressure ^ LPG - Liquid Propane Gas ^ EEC - Electronic Engine Control NOTE THE FOLLOWING IS A LIST OF KNOWN MIS-DIAGNOSIS OF THE COMPUVALVE REPLACEMENT ON BI-FUEL VEHICLES. 1. MAP line loose. 2. High FAP from vaporizer breakdown. 3. Incorrect interpretation of DTCs. 4. VCL replacement due to harness faults. 5. Misfire due to leaking 0-rings. 6. Compuvalve replaced without checking HPS circuit for correct resistance. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Alternative Fuel Control Module > Component Information > Technical Service Bulletins > Bi-Fuel System - Compuvalve Replacement > Page 4862 7. Low FAP due to lockoff fault. 8. LPG fuel filter in backward. COMPUVALVE PRE-REPLACEMENT CHECKLIST 1. Check communication ability with EEC, AFCM/compuvalve and VCL and compuvalve. Follow the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop Manual procedures for the appropriate vehicle. 2. Check MAP line. Follow normal diagnostic methods and visual checks. 3. Check harness and connection integrity. Follow normal diagnostic methods, basic circuit checks and harness connections. 4. Check current bi-fuel EEC calibration code. Refer to WDS. 5. Check fuel gauge with fuel selector switch in ALT position for fuel level. 6. Check power to compuvalve. Power to the compuvalve is indicated by the following fuel selector switch light status: On steady = OK, On then Off or Flashing (regular and irregular) indicated fault. 7. Check that the arrow on the LPG fuel filter is pointing in the direction of fuel flow. 8. Check base vehicle. Run vehicle in gas mode (e.g., borderline secondary ignition). Follow normal diagnostic methods. 9. Check other applicable TSBs and special service messages. 10. Verify ALT fuel switch status. Refer to Section 1 of the appropriate PC/ED Workshop Manual. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 490000, 602300, 603300, 608000, 609000, 611000, 623000, 690000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations Fuel Pump Relay: Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 4866 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 4867 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4870 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4871 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4872 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4873 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4874 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4875 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4876 Fuel Pump Relay: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4877 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4878 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4879 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4880 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4881 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4882 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 4883 Fuel Pump Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Page 4884 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations > Page 4888 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay Main Relay (Computer/Fuel System): Testing and Inspection PCM Power Relay Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Testing and Inspection > PCM Power Relay > Page 4891 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: Customer Interest Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4901 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Customer Interest for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4902 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4908 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Flow Meter/Sensor: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 4909 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 4910 Air Flow Meter/Sensor: Specifications Mass Airflow Sensor (MAF) Plate Nuts 8-11.5 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 4911 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 4912 Air Flow Meter/Sensor: Service and Repair REMOVAL WARNING: DO NOT DISASSEMBLE THE MAF SENSOR. THE SENSOR CAN BE DAMAGED BY TOUCHING. 1. Disconnect the battery ground cable. 2. Open the engine air cleaner. ^ Disconnect the Mass Air Flow (MAF) sensor connector from the wiring harness. ^ Release the air cleaner clamp. ^ Separate the inlet side of the air cleaner from the outlet side of the air cleaner. 3. Cut the tape on the wire loom of the extension harness. ^ Peel back the wire loom from the extension harness near the grommet in the air cleaner. CAUTION: Do not cut the MAF sensor wires when cutting the tape on the wire loom. 4. Remove the grommet from the outlet side of the air cleaner and slide the grommet down the extension harness. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Technical Service Bulletins > Page 4913 5. Remove the MAF sensor plate and mass air flow sensor from the outlet side of the engine air cleaner. 6. Disconnect the MAF sensor connector. 7. Remove the nuts and separate the MAF plate from the mass air flow sensor. INSTALLATION 1. Follow the removal procedure in reverse order. CAUTION ^ Do not tamper with the MAF sensing elements located in the airflow bypass; tampering may result in unit failure. ^ The grommet used to seal the engine air cleaner housing at the extension harness must be fully seated. Failure to do so will result in unmetered air entering the engine. NOTE ^ The MAF sensor module and body are calibrated and replaced as a unit. ^ Use the alignment notch to properly align the inlet side and the outlet side of the engine air cleaner. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Specifications Inertia Fuel Shutoff Switch: Specifications Intertia Fuel Shutoff Switch Bolts .............................................................................................................................................. 1.6-2.2 N.m (14.2-19 Lb-In) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position (TP) Sensor Screws 2.8-3.4 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 4920 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the shield. 3. Remove the throttle position sensor. 1 Disconnect the connector. 2 Remove the bolts. 3 Remove the throttle position sensor. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 4921 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications Throttle Body: Specifications Throttle body bolts 9 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 4925 Throttle Body: Description and Operation The throttle body: ^ controls air supply to the upper intake manifold by positioning the throttle plate. ^ connects the accelerator cable and if equipped the speed control actuator cable to the throttle plate. ^ is not adjustable. ^ cannot be cleaned. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 4926 Throttle Body: Service and Repair REMOVAL WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. CAUTION: The throttle body bore and plate area have a special coating and cannot be cleaned, or damage to the throttle body may occur. 1. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the accelerator control splash shield. 2. Remove air cleaner outlet tube. 3. Disconnect the connector. 4. Disconnect the throttle controls. 1 Disconnect the speed control cable. 2 Disconnect the accelerator cable. 3 Remove the throttle return spring. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 4927 5. Remove the throttle body. 1 Remove the bolts. 2 Remove the (A) throttle body and the (B) throttle body gasket. NOTE: Discard the throttle body gasket. INSTALLATION 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications Throttle Cable/Linkage: Specifications Accelerator Cable Bracket Bolts 6 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications > Page 4931 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications > Page 4932 Throttle Cable/Linkage: Service and Repair REMOVAL 1. Disconnect the accelerator cable from the accelerator pedal and shaft. 2. Remove the left hand side accelerator control splash shield bolts. 3. Remove the right hand side splash shield bolt and remove the splash shield 4. Remove the accelerator cable from the cable clip. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications > Page 4933 5. Depress the accelerator cable lock tabs on the inside of the passenger compartment and push the accelerator cable into the engine compartment. 6. Disconnect the accelerator cable from the throttle lever. 1 Rotate the throttle lever forward. 2 Slide the accelerator cable end from the throttle lever. 7. Depress the accelerator cable lock tabs and remove the accelerator cable from the accelerator cable bracket. Remove the accelerator cable. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications > Page 4934 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications Throttle Position Sensor: Specifications Throttle Position (TP) Sensor Screws 2.8-3.4 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 4938 Throttle Position Sensor: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the accelerator control splash shield. 1 Remove the bolts. 2 Remove the shield. 3. Remove the throttle position sensor. 1 Disconnect the connector. 2 Remove the bolts. 3 Remove the throttle position sensor. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 4939 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications Firing Order: Specifications The RH (Passenger's) side ................................................................................................................. ................................................ Cylinders 1, 2, 3, and 4 The LH (Driver's side) .......................................................................................................................... ............................................. Cylinders 5, 6, 7 and 8 Firing Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4956 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4957 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4958 DISCLAIMER Service Procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4959 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4960 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4961 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4962 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4963 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4964 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4965 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4966 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4967 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4968 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4974 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4975 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4976 DISCLAIMER Service Procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4977 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4978 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4979 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4980 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4981 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4982 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4983 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4984 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4985 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4986 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 4987 Camshaft Position Sensor: Specifications Camshaft Position (CMP) Sensor Bolt 8-12 Nm Camshaft Position Sensor 8-12 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 4988 Camshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Camshaft Position (CMP) sensor 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the camshaft position sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4997 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4998 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 4999 DISCLAIMER Service Procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5001 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5002 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5003 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5004 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5005 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5006 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5007 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5008 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5009 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference Oil Pressure Gauge: All Technical Service Bulletins Oil Pressure Sending Unit - Drip Shield Interference Article No. 01-4-2 3/05/01 ENGINE - 5.4L - OIL SENDING UNIT INTERFERENCE FIT AT ENGINE OIL DRIP SHIELD - 4X4 VEHICLES EQUIPPED WITH 5.4L ENGINE ONLY FORD: 1998 F-250 LD 1998-2001 EXPEDITION, F-150 1999-2001 SUPER DUTY F SERIES LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit the engine oil sending unit contacting the oil drip shield attached to the front axle. This may be caused by tight tolerances between the engine oil sending unit and the engine oil drip shield. This may cause a malfunction of the engine oil sending unit. ACTION If the engine oil sending unit needs to be replaced due to contact with the drip shield, modify the engine oil drip shield as shown. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE IF THE ENGINE OIL SENDING UNIT NEEDS TO BE REPLACED IN SERVICE, MODIFY THE ENGINE OIL DRIP SHIELD BEFORE INSTALLING THE NEW ENGINE OIL SENDING UNIT. 1. Remove oil drip shield from front axle. This shield is attached to the front axle by three (3) bolts. 2. Modify shield as shown (Figure 1). Remove excess material from shield. Remove any sharp edges or burrs upon finishing cutting operation. 3. Reinstall engine oil drip shield. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference > Page 5015 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODE OASIS CODES: 401000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 01-4-2 > Mar > 01 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 01-4-2 > Mar > 01 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5025 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 01-4-2 > Mar > 01 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5026 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 01-4-2 > Mar > 01 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5027 DISCLAIMER Service Procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 01-4-2 > Mar > 01 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5028 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 01-4-2 > Mar > 01 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5029 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 01-4-2 > Mar > 01 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5030 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 01-4-2 > Mar > 01 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5031 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 01-4-2 > Mar > 01 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5032 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 01-4-2 > Mar > 01 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5033 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 01-4-2 > Mar > 01 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5034 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 01-4-2 > Mar > 01 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5035 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 01-4-2 > Mar > 01 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5036 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hall Effect Sensor: > 01-4-2 > Mar > 01 > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5037 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil Pressure Gauge: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil Pressure Gauge: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5043 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil Pressure Gauge: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5044 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil Pressure Gauge: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5045 DISCLAIMER Service Procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil Pressure Gauge: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5046 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil Pressure Gauge: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5047 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil Pressure Gauge: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5048 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil Pressure Gauge: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5049 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil Pressure Gauge: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5050 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil Pressure Gauge: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5051 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil Pressure Gauge: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5052 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil Pressure Gauge: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5053 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil Pressure Gauge: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5054 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil Pressure Gauge: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5055 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips Ignition Coil: Technical Service Bulletins Ignition System - Coil-On-Plug Misfire Diagnostic Tips TSB 05-22-8 11/14/05 WDS COP KIT DIAGNOSTIC TIPS - COIL ON PLUG (COP) IGNITION SYSTEMS - ENGINE MISFIRE OR ROUGH RUNNING FORD: 1996-1999 Taurus SHO 1998-2006 Crown Victoria, Mustang 2000 Taurus 2002-2005 Thunderbird 2003-2006 Focus 2004-2006 Taurus 2005-2006 Five Hundred, Freestyle 1997-2006 E-Series, Expedition, F-150 1999-2006 F-Super Duty 2000-2005 Excursion, F-53 2001-2006 Escape 2002-2005 Explorer 2005-2006 Escape Hybrid LINCOLN: 1997-1998 Mark VIII 1998-2002 Continental 1998-2006 Town Car 2000-2006 LS 1998-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator MERCURY: 1998-2006 Grand Marquis 2000 Sable 2004-2005 Sable 2005-2006 Montego 2002-2005 Mountaineer 2005-2006 Mariner 2006 Mariner Hybrid This article supersedes TSB 04-16-01 to update the vehicle applications and model years. NOTE FOLLOW THIS TSB PROCEDURE ONLY IF THERE ARE NO SPECIFIC MISFIRE TSBs/SSMs RELEASED FOR THE VEHICLE SYMPTOM BEING EXPERIENCED. ISSUE Approximately 50% of coil on plug (COP) coils returned for warranty do not have a problem. ACTION The misfiring cylinder must be identified through Self-Test misfire codes or through WDS Power Balance. Rule out base engine problems, rule out fuel problems, and then look at ignition problems (be sure to rule out coil primary circuit issues). Once the above steps have been completed, and the issue is in the secondary part of the ignition system, the oscilloscope procedure outlined in this TSB can isolate the difference between a coil or spark plug problem. SERVICE PROCEDURE The optional WDS COP Kit available through Rotunda will provide more accurate diagnosis and help reduce replacement of non-defective parts. The Kit (418-F5528) can be purchased through 1-800-ROTUNDA. The following material will detail the diagnostic steps on WDS to take the guesswork out of misfire diagnosis using the COP Kit. The following procedure is for cylinder specific misfires and not random misfires. Random misfires have a different root cause and are not covered by this TSB. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 5060 Misfire Definition: A misfiring cylinder is lacking power relative to the other cylinders. The causes for a cylinder specific misfire could be fuel, spark, or mechanical problems. Perform a thorough visual inspection. If no visible concerns are found use the following WDS tools for misfire diagnosis: ^ Self-test (Check for codes first) Power Balance (Identify the cylinder of concern) ^ Relative Compression (Rule out a possible mechanical issue) ^ Fuel (Make sure fuel injectors are not restricted) ^ Ignition (Make sure spark plugs and coils are working properly) ^ Oscilloscope (Detailed signal analysis) NOTE USE THE ENCYCLOPEDIA BUTTON IN THE LOWER LEFT CORNER OF THE SCREEN FOR DETAILED INFORMATION ON THE WDS TOOL BEING DISPLAYED. If there is a self-test code identifying a particular cylinder then you just need to determine if it is a fuel, ignition, or possibly a mechanical problem. Proceed to Step 2 after running Relative Compression to rule out any mechanical issues. If there is no self-test code and the customer concern is a miss, proceed to Step 1. Step 1: (Select Toolbox Icon, then Powertrain, then Power Balance) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 5061 The cylinder specific miss has to be identified as shown in the example in Figure 2 in order to proceed with the remaining steps. If the miss does not occur at idle (in the bay), try to brake torque the engine. This extra loading should reproduce the miss in the bay. If the miss cannot be reproduced during brake torque, select Relative Compression under Powertrain on WDS before going on a road test to rule out mechanical problems. If Relative Compression shows a problem then the base engine issue must be serviced. If Relative Compression results are good (Figure 3), road test under as many different driving conditions as possible until the miss occurs on Power Balance. Some misses may be very intermiffent so be patient and concentrate on steady load conditions. Once a cylinder dropout is identified proceed to Step 2. Step 2: (Select Toolbox Icon, then Powertrain, then Fuel System Test) Run Fuel System Test on WDS to determine if there may be a fuel problem. After completing fuel Pressure/Leakdown test, select Injector flow to isolate Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 5062 a restricted injector as shown in Figure 4. If all the injectors are within specification, proceed to Step 3. Step 3: (Select Toolbox Icon, then Powertrain, then Ignition System Test) Run Ignition System Test on WDS to determine if there is an ignition problem. Look at both duration (DUR) and kilovolts (KV) and look for values that standout from the rest as shown in Figure 5 and Figure 6. NOTE LIVE DISPLAY HAS TO AVERAGE IGNITION VALUES BECAUSE THERE IS TOO MUCH DATA TO DISPLAY. MAKE A CAPTURE TO VIEW EACH ENGINE EVENT WITHOUT AVERAGING. THIS CAN BE HELPFUL WHEN THE PROBLEM IS INTERMITTENT. IF THE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 5063 MISS IS EXTREMELY INTERMITTENT AND DOES NOT SHOW UP IN IGNITION, PROCEED TO STEP 4. If either spark duration or peak KV on the Red Probe (Suspect Cylinder) are offset from the values displayed on the Black Probe (Known Good Cylinder) then the problem is in the ignition system. Rule out coil primary circuit issues before proceeding to coil secondary issues such as the spark plug , coil boot, or possibly the coil. Use the WDS Oscilloscope with the COP kit to determine if the issue is the coil or the spark plug. Step 4: (Select Toolbox, then Oscilloscope) WARNING SECONDARY IGNITION VOLTAGES ARE VERY HIGH. KEEP HANDS AND TOOLS AWAY FROM THE END OF THE COIL THAT SUPPLIES THE SPARK. SET-UP: With the engine off, pull the suspect coil from the cylinder well and turn it upside down so the coil cannot spark to any other surface as shown in Figure 1. Wrap a clean shop cloth around the hard shell of the coil to help keep the coil propped up and stable. CAUTION THE COIL BOOT CAN BE DAMAGED IF THE COIL SPARKS TO ANOTHER SURFACE DURING THIS PROCEDURE. Keep the coil connected to the harness and leave the WDS COP clip attached to the coil. Route the coil clip wire and cable away from the coil being tested as well as other coils to avoid noise interference. Disconnect the injector of the cylinder being tested so raw fuel is not washing the cylinder. This is a stress test for the coil. The type of waveform displayed on the oscilloscope will show whether a coil or the plug is the problem if all previous steps have been followed. Keep hands and tools away from the end of the coil that supplies the spark. COP Stress Test Procedure: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 5064 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition System - Coil-On-Plug Misfire Diagnostic Tips > Page 5065 Go to the Oscilloscope Tool and select Channel 3, then select Auto, then select COP_STRESS_TEST_RED. This pre-configured setting will zoom-in on the peak firing of the coil being tested. Start the engine and be sure the coil is not sparking to any surface. If the coil is sparking to other surfaces, turn the engine off immediately and readjust the coil so it cannot spark to any other surface. Restart the engine and touch the Red Man icon to start the oscilloscope. All settings are pre-configured and no adjustments are necessary. Compare the waveform you get with the examples provided in Figures 7, 8, and 9). Figure 7 is a good waveform. If your waveform is similar to Figure 7 the coil is working correctly. Suspect the spark plug. Figure 8 and Figure 9 are examples of problem coils. Replace the coil if the waveform is similar to Figures 8 or 9. The coil is causing the misfire when the peak firing appears like those shown in Figures 8 and 9. Notice the difference in the peak-firing signal when compared to the good peak signal in Figure 7. Figure 9 shows a more dramatic fault in the peak failure. Most root causes of misfire issues can be identified quickly using the steps outlined above. Some misfire issues can be difficult making the oscilloscope an important part of your diagnostic toolbox. OTHER APPLICABLE ARTICLES: 05-13-4 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Electrical Specifications Ignition Coil: Electrical Specifications Ford does not provide standalone testing for this component. The only test provided by Ford for the ignition coil is a pinpoint test procedure. Refer to Powertrain Management/ Computers and Control Systems/ Testing and Inspection/ With EEC (OBD II-A System)/ Trouble Code Diagnostic Charts (Pinpoint Tests/No Start)/ JF - Integrated Ignition Coil on Plug 1-10 Failure. See: Computers and Control Systems/Testing and Inspection/Pinpoint Tests/JF - Integrated Ignition Coil on Plug 1-10 Failure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Electrical Specifications > Page 5068 Ignition Coil: Mechanical Specifications Coil On Plug (COP) Bolt 4.5-7 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 5069 Ignition Coil: Description and Operation The ignition coil: - changes the low voltage signal from the Powertrain Control Module (PCM) to high-voltage pulses. - produces the high-voltage pulses to the spark plugs. - connects directly to the spark plug. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 5070 Ignition Coil: Service and Repair REMOVAL 1. Disconnect the coil on plug electrical connection. 2. Remove the bolts. 3. Remove the coil on plug. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 5071 1. Follow the removal procedure in reverse order. NOTE: Apply Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A meeting Ford specification ESE-M1C171A or equivalent to the inside of the coil boots. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Linear Knock Sensor 16.2-23.8 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Specifications > Page 5075 Knock Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Remove the knock sensor. 1 Disconnect the connector. 2 Remove the knock sensor. NOTE: This engine is equipped with a unique linear knock sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5085 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5086 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5087 DISCLAIMER Service Procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5088 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5089 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5090 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5091 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5092 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5093 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5094 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5095 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5096 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5097 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5103 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5104 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5105 DISCLAIMER Service Procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5106 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5107 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5108 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5109 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5110 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5111 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5112 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5113 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5114 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Camshaft Position Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5115 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 5116 Camshaft Position Sensor: Specifications Camshaft Position (CMP) Sensor Bolt 8-12 Nm Camshaft Position Sensor 8-12 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Technical Service Bulletins > Page 5117 Camshaft Position Sensor: Service and Repair REMOVAL 1. Remove the Camshaft Position (CMP) sensor 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the camshaft position sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5126 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5127 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5128 DISCLAIMER Service Procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5129 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5130 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5131 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5132 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5133 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5134 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5135 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5136 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5137 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > Customer Interest for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5138 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set Technical Service Bulletin # 02-22-1 Date: 021111 Engine Controls - Engine Surge/Rolling Idle/DTC's Set Article No. 02-22-1 11/11/02 ^ DRIVEABILITY - SURGE/ROLLING IDLE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION ^ ENGINE - GEAR DRIVEN SYNCHRONIZERS - INCORRECT INSTALLATION - CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION FORD: 1994-1997 THUNDERBIRD 1995-2003 TAURUS 1996-2003 MUSTANG 1995-1997 AEROSTAR 1995-2003 RANGER, WINDSTAR 1996-2000 EXPLORER 1997-2003 E SERIES, F-150 MERCURY: 1994-1997 COUGAR 1995-2003 SABLE 1997-2000 MOUNTAINEER ISSUE Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies may be hard to diagnose. Vehicle may exhibit poor fuel economy, driveability Diagnostic Trouble Codes (DTCs) P1336, P1309, P0340 with MIL light on. Loss of power, surge, hesitation and runs rough on acceleration may also be present. ACTION New diagnostics have been developed for WDS to diagnose incorrectly installed gear driven camshaft position (CMP) synchronizer assemblies. Refer to the following Service Procedure to diagnose a possible mis-installed synchronizer assembly and proper installation procedure. SERVICE INFORMATION Items Covered In This Article ^ "Hall" vs. "VRS" sensor function ^ Vehicle history scrutiny for past service of the synchronizer assembly ^ WDS - Power balance test ^ WDS - CMP and CKP wave signal comparison ^ Wave Comparison chart - CMP vs. CKP ^ Correct (CMP) synchronizer installation tool application & installation procedure ^ "Top Dead Center" (TDC) alignment ^ Synchronizer installation tool application chart Hall - Effect (Hall) and Variable Reluctance (VRS) CMP Sensors Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5144 CMP sensors are used on all current model year engines, regardless of fuel system or ignition system type. The CMP sensor provides the Powertrain Control Module (PCM) with cam position information to indicate # 1 cylinder, on the compression stroke There are two different types of CMP sensors: ^ The three-pin, Hall-effect sensor (Figure 1) ^ The two-pin Variable Reluctance sensor (Figure 1) Although the Hall-effect (three-pin) and the Variable Reluctance (two-pin) CMP sensors perform the same function, their signal appearance is quite different and they are not interchangeable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5145 ^ The three-pin Hall-effect sensor uses a Hall effect device and a magnet to generate a digital square wave signal (Figure 2) ^ The two-pin Variable Reluctance sensor is a magnetic transducer, which uses differential voltage across windings to generate a voltage waveform that is similar to a sine wave (Figure 2) Both sensors provide a switching voltage as the engine rotates. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5146 DISCLAIMER Service Procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5147 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5148 If you suspect that a vehicle (engine) may have had the synchronizer assembly (Figure 3) installed incorrectly, check the vehicle history to see if related service has been performed. If you determine that the synchronizer could have been installed incorrectly, use the following procedure with WDS to verify correct installation (Figure 5). NOTE CORRECT CAMSHAFT POSITION SYNCHRONIZER ASSEMBLY INSTALLATION IS CRITICAL. AN INCORRECTLY INSTALLED SYNCHRONIZER CAN CAUSE HARD TO DIAGNOSE DRIVEABILITY CONDITIONS AND POSSIBLE SERIOUS ENGINE DAMAGE. Reasons for incorrect installation are: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5149 ^ Not setting the # 1 cylinder on Top Dead Center (TDC) of the compression stroke ^ Use of the incorrect camshaft synchronizer tool for installation ^ Incorrect alignment of the synchronizer tool Power Balance Test In WDS The WDS Power Balance Test can be used to quickly determine if the CMP synchronizer assembly is installed incorrectly. Use the following procedure. 1. Run the vehicle while viewing the power balance test in WDS to insure that no engine misses are occurring. 2. Shut the engine off and remove the # 1 cylinder injector electrical connector. 3. Start the engine and view the WDS power balance test. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5150 4. The test should indicate a power loss in the # 1 cylinder (Figure 4). ^ If the # 1 cylinder is indicated, then the CMP synchronizer assembly IS NOT grossly mis-installed. (Figure 4) Continue to Step 5 in this procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5151 ^ If any other cylinder is indicated during the power balance test, then the CMP synchronizer assembly HAS BEEN INSTALLED INCORRECTLY, and must be reinstalled. (Refer to the installation procedure, tool chart shown and TDC reference described in this TSB, or refer to the appropriate model year Workshop Manual Section 303-14, Synchronizer-Camshaft). 5. If power loss is indicated in the # 1 cylinder (Figure 4), connect a 104 pin break-out box between the PCM and the PCM electrical connector. 6. Insert the red WDS probe into pin # 21 and the black WDS probe into pin # 85 of the break-out Box. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5152 7. Select oscilloscope from the WDS Toolbox. 8. Select "Channel one Auto Mode", then select the Crankshaft Position (CKP) sensor. 9. Select "Channel two Auto Mode", then select the CMP sensor based on whether it is a VRS (2-pin) or Hall-effect (3 pin) CMP sensor. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5153 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5154 10. Press the start button and view both the CKP sensor as well as the CMP sensor signals. Figures 6, 7 and 8). 11. Compare the wave forms of both sensors. ^ The missing tooth of the CKP sensor trigger wheel will be shown on the screen as an extra space between the wave forms. This position is 60° Before Top Dead Center (BTDC) ^ The upper peaks of the wave form are each spaced 10° of crankshaft rotation apart ^ The CMP timing setting on all current 6-cylinder engines should be between 10 and 40° After Top Dead Center (ATDC) On all Hall-effect sensors, the CMP wave form rising edge should occur between the 7th and the 10th peak past the missing tooth. (Figure 6) On the VRS sensors (except 5.0L engines), the falling edge of the CMP waveform should cross the zero reference line between the 7th and 10th peak past the missing tooth waveform. (Figure 7). On 5.0L engines With a VRS CMP sensor, the falling edge waveform should cross the zero reference line between the 6th and the 9th peak past the CKP missing tooth (Figure 8). On 5.0L engines with a Hall-effect VRS CMP sensor, the rising edge of the wave form should occur between the 6th and 9th peak past the CKP missing tooth wave form. (CMP) SYNCHRONIZER INSTALLATION PROCEDURE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5155 1. Set the # 1 cylinder on Top Dead Center (TDC) of the compression stroke. NOTE THE # 1 CYLINDER MUST BE SET ON TOP DEAD CENTER (TDC) OF THE COMPRESSION STROKE OR THE SYNCHRONIZER ASSEMBLY WILL NOT BE INSTALLED CORRECTLY. 2. Disconnect the battery ground cable. 3. Remove the CMP sensor from the synchronizer assembly. 4. Remove the synchronizer clamp (hold down bolt) and remove the synchronizer assembly. NOTE IN SOME CASES THE OIL PUMP INTERMEDIATE SHAFT MAY NOT COME OUT WITH THE SYNCHRONIZER ASSEMBLY. IF SO, RETRIEVE THE INTERMEDIATE SHAFT BEFORE PROCEEDING. 5. After performing the required service and before beginning the installation of the synchronizer assembly, ALWAYS COAT THE SYNCHRONIZER DRIVE GEAR WITH CLEAN ENGINE OIL PRIOR TO INSTALLATION. 6. Install the correct engine and model year synchronizer alignment installation tool. Install the tool to the synchronizer assembly by rotating the tool until it engages the notches in the camshaft synchronizer housing and the armature (Figure 10). CAUTION SOME OF THE TOOLS WILL FIT ACROSS ENGINE LINES AND COULD BE PERCEIVED AS BEING THE CORRECT TOOL. ALTHOUGH THE TOOLS MAY APPEAR SIMILAR, THERE ARE SUBTLE DIFFERENCES BETWEEN THEM, ALWAYS CHECK THE TOOL APPLICATION CHART PROVIDED IN THIS TSB (FIGURE 9). 7. During the installation of the synchronizer assembly (with the tool attached) into the engine, the arrow on the tool will rotate until the intermediate shaft and the camshaft gear fully engage. NOTE THE ARROW WILL ROTATE CLOCKWISE OR COUNTER CLOCKWISE DEPENDING ON THE ENGINE TYPE AND ENGINE ROTATION. 8. Install the camshaft synchronizer assembly so the arrow on the installation tool (Figure 3) is in the correct position as specified in the appropriate model year vehicle and engine. (Refer to Workshop Manual Section 303-14, Synchronizer-Camshaft). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Hall Effect Sensor, Ignition > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hall Effect Sensor: > 02-22-1 > Nov > 02 > Engine Controls - Engine Surge/Rolling Idle/DTC's Set > Page 5156 9. Install the synchronizer clamp (bolt) before removing the installation tool. Tighten to 18 Lb-ft (25 N.m). 10. Remove the installation tool. 11. Install the CMP sensor. Tighten to 27 Lb-in (3 N.m). 12. Install battery ground cable. CAUTION DO NOT LOOSEN THE SYNCHRONIZER BOLT AND ROTATE THE SYNCHRONIZER ASSEMBLY. THE SYNCHRONIZER ASSEMBLY IS NOT ADJUSTABLE; DO NOT LOOSEN THE SYNCHRONIZER BOLT AFTER THE ALIGNMENT TOOL HAS BEEN REMOVED IN ORDER TO ALIGN THE CMP ELECTRICAL CONNECTOR FOR ANY REASON. IF THE ELECTRICAL CONNECTOR IS NOT IN THE CORRECT POSITION, THE SYNCHRONIZER ASSEMBLY HAS TO BE REMOVED, THE ALIGNMENT TOOL REINSTALLED AND THE ASSEMBLY REINSTALLED ASSUMING THE ENGINE HAS NOT BEEN ROTATED FROM TDC OF THE COMPRESSION STROKE ON # 1 CYLINDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000, 499000, 608000, 608500, 610000, 610500, 611000, 611500, 612000, 612500, 614000, 614500, 622000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 5162 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 5163 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 5164 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 5165 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 5166 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 5167 Ignition Switch Lock Cylinder: Specifications TORQUE SPECIFICATIONS Lock Cylinder Housing Screws .................................................................................................................................................. 18-26 Nm (14-19 ft. lbs.) Key Release Button Bolt ............................................................................................................................................................ 4-6 Nm (36-53 inch lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Lock Cylinder Ignition Switch Lock Cylinder: Service and Repair Functional Lock Cylinder Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1. Insert the ignition key and turn to the RUN position. 2. Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock cylinder. Installation 1. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Lock Cylinder > Page 5170 Ignition Switch Lock Cylinder: Service and Repair Key Release Button Removal 1. Remove the ignition switch lock cylinder. 1. Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2. Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. 2. Twist the tilt wheel handle and shank and remove. 3. Release the four clips and remove the steering column opening cover. 4. Remove the upper and lower steering column shrouds. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Lock Cylinder > Page 5171 1. Remove the three screws. 2. Remove the lower steering column shroud. 3. Remove the upper steering column shroud. 5. Remove the key release button. 1. Remove the bolt. 2. Remove the spring. 3. Remove the key release button. Installation 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Lock Cylinder > Page 5172 Ignition Switch Lock Cylinder: Service and Repair Non-Functional Lock Cylinder Removal WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Lock Cylinder > Page 5173 4. Remove the ignition switch lock cylinder. ^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. ^ Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. ^ Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. 6. Remove the bearing and the gear. ^ Thoroughly clean all drill shavings from the steering column and inspect it for damage. Installation The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Lock Cylinder > Page 5174 1. NOTE: Use a new ignition switch lock cylinder. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications Knock Sensor: Specifications Linear Knock Sensor 16.2-23.8 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 5178 Knock Sensor: Service and Repair REMOVAL 1. Remove the intake manifold. 2. Remove the knock sensor. 1 Disconnect the connector. 2 Remove the knock sensor. NOTE: This engine is equipped with a unique linear knock sensor. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Gap Spark Plug: Specifications Spark Plug Gap 1.32-1.42 mm Spark Plugs 15 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Gap > Page 5183 Spark Plug: Specifications Spark Plug Gap 1.32-1.42 mm Spark Plugs 15 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 5184 Spark Plug: Application and ID Original Spark Plug .............................................................................................................................. ............................................................... AWSF12E Replacement Spark Plug ................................... ................................................................................................................................................... AWSF12E Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 5185 Spark Plug: Description and Operation The spark plug: ^ changes high-voltage pulses to sparks at gap which ignites fuel and air mixture. ^ originally equipped on the vehicle; has a platinum-enhanced active electrode for long life. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 5186 Spark Plug: Service and Repair REMOVAL 1. Remove the Coil On Plug (COP). Remove the screw and the coil for each plug. NOTE: Remove any foreign debris from the spark plug wells with compressed air. 2. Remove the RH spark plugs. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 5187 3. Remove the LH spark plugs. 4. Inspect the spark plugs for: - Deposits bridging spark plug gap (A). - Wet black deposits (oil fouling) (B). - Dry black deposits (carbon fouling) (C). - Overheating (D). - Deposits fused on spark plug (E). - Pre-ignition damage (F). - Normal spark plug (G). 5. Adjust the spark plug as required. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 5188 INSTALLATION 1. Install the LH spark plugs. 2. Install the RH spark plugs. 3. Install the COPs. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair Pressure Regulating Solenoid: Service and Repair Electronic Pressure Control (EPC) Solenoid Removal 1. Remove the manual control lever. 2. CAUTION: Do not pull on the plastic lead frame. This may cause damage to the connector ends. Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame from the solenoids. Disconnect the molded lead frame from the solenoids. 1 Disconnect the shift solenoid SSA and SSB. 2 Disconnect the Torque Converter Clutch (TCC). 3 Disconnect the Electronic Pressure Control (EPC) solenoid. 4 Disconnect the bulkhead inter-connector. 3. Remove the EPC solenoid. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Page 5195 1. Install the EPC solenoid. 2. Connect the molded lead frame to the solenoids. - Connect the bulkhead inter-connector. - Connect the Electronic Pressure Control (EPC) solenoid. - Connect the Torque Converter Clutch (TCC). - Connect the shift solenoid SSA and SSB. 3. Install the manual control lever. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications Shift Interlock Solenoid: Specifications Shift Lock Actuator Bolts 7-11 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 5199 Shift Interlock Solenoid: Service and Repair Removal 1. Remove the steering column assembly. 2. Remove the insert plate and shift lock actuator. 1 Remove the bolts. 2 Remove the insert plate and shift lock actuator. 3. NOTE: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to be replaced in the field. Remove the insert plate from the shift lock actuator. Remove and discard the shift lock actuator clip. Installation 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair Shift Solenoid: Service and Repair Refer to Valve Body for service procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications TCC Solenoid Bolt 9-11 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications Transfer Case Actuator: Specifications Shift Motor Bolts .................................................................................................................................. ............................................. 10 Nm (89 inch lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 5210 Transfer Case Actuator: Service and Repair Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Disconnect the shift motor electrical connector. 3. Remove the coil wire from the electric shift motor electrical connector. 1 Remove the wire connector spacer. 2 Remove the coil wire and pin. Use correct electrical connector pin remover. 4. Remove the transfer case shift motor. 1 Remove the bolts. 2 Remove the transfer case shift motor. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 5211 1. Install the transfer case shift motor. 1 Position the transfer case shift motor. 2 Install the bolts. 2. Install the coil wire into the transfer case shift motor electrical connector. 1 Install the coil wire and pin. 2 Install the wire connector spacer. 3. Connect the transfer case shift motor electrical connector. 4. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Adjustments Shift Indicator: Adjustments 1. Remove the upper instrument panel steering column cover. 2. Place the gearshift lever in the (D) position. - Rotate the gearshift lever clockwise until it bottoms out (first gear), then rotate two detents counterclockwise (D) position). 3. Hang an eight pound weight on the gearshift lever. 4. Center the pointer in the middle of the (D) position. - Rotate the thumb wheel located on the bottom of the steering column to adjust the pointer. 5. Remove the eight pound weight. 6. Carefully move the gearshift lever from detent to detent and compare with transmission settings. Readjust if necessary. 7. Install the upper instrument panel steering column cover. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Four Wheel Drive Indicator Lamp: Customer Interest Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 5226 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Four Wheel Drive Indicator Lamp: All Technical Service Bulletins Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 5232 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > 4X4 High Indicator Four Wheel Drive Indicator Lamp: Description and Operation 4X4 High Indicator The 4X4 high indicator will be illuminated when the vehicle is in 4X4 high mode and the GEM sends a ground signal to the instrument cluster. The 4X4 high indicator will prove out when the ignition switch is placed in the START position and then in the RUN position. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > 4X4 High Indicator > Page 5235 Four Wheel Drive Indicator Lamp: Description and Operation Low Range Indicator The LOW RANGE indicator Will be illuminated when the vehicle is in 4X4 low and the Powertrain Control Module (PCM) sends a message to the instrument cluster via the SCP network. The low range indicator will prove out when the ignition switch is placed in the START position and then in the RUN position. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Page 5236 Four Wheel Drive Indicator Lamp: Testing and Inspection Refer to Instrument Panel/Testing and Inspection/Procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts Control Module: Customer Interest Transfer Case - Inadvertent Shifts Article No. 01-14-1 07/23/01 ^ ELECTRICAL - ELECTRONIC SHIFT ON THE FLY (ESOF) TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS ^ TRANSMISSION - TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS VEHICLES EQUIPPED WITH ELECTRONIC SHIFT ON THE FLY (ESOF) ONLY FORD: 1999 F-250 LD 1999-2001 EXPEDITION, F-150 LINCOLN: 1999-2001 NAVIGATOR ISSUE Some vehicles may exhibit inadvertent 4X4 Hi or Low shift events, 4X4 and/or Low Range indicator flashing or solid or vehicle stuck in 4L after uncommanded shift. This may be caused by the 4X4 shift motor. ACTION Install a YL1Z-7G360-AA shift motor on vehicles built before 12/99. The YL1Z-7G360-AA shift motor with a grey contact plate cover replaces the prior design F75Z-7G360-AA motor with a blue contact plate cover. Grey cover shift motors contain improved sense plate material and shift motor terminal upgrade. For vehicles already equipped with the latest style shift motor, refer to the following Service Procedure for details. SERVICE PROCEDURE For overall description and operation of the Electronic Shift On The Fly (ESOF) Transfer Case refer to Section 308-07 of the appropriate model year Workshop Manual. NOTE ALL DIAGNOSIS BY SYMPTOM SECTIONS HEREIN ARE WRITTEN ASSUMING THAT VEHICLE IS ALREADY EQUIPPED WITH THE LATEST STYLE SHIFT MOTOR. ALWAYS REPLACE SHIFT MOTOR AS A FIRST STEP IF CURRENT MOTOR IS PRIOR LEVEL WITH BLUE COVER. NOTE TO RESET THE GEM'S 4X4 MONITORING SOFTWARE, USE CLEAR DTC COMMAND IN THE NGS OR WOS TESTER (EVEN IF NO DTC'S ARE AVAILABLE) AND CYCLE IGNITION KEY ON-OFF-ON. RECORD ANY CONTINUOUS MEMORY CODES PRIOR TO CLEARING DTCs. NOTE AN UNCOMMANDED 4H OR 4L SHIFT DUE TO FALSE SHIFT MOTOR CONTACT PLATE SIGNAL MAY OR MAY NOT BE ACCOMPANIED BY SHIFT MOTOR DTC'S P1838, P1846, P1850, P1854, P1858, P1866, AND/OR P1867 STORED IN THE GEM DEPENDING ON WHETHER THE IGNITION KEY WAS CYCLED AFTER THE EVENT. NOTE CONTACT PLATE PIDS READ OPPOSITE OF 1999 OR EARLIER WORKSHOP MANUALS WHEN VIEWED WITH NGS RED CARD VERSIONS 15.0 OR LATER. THIS TSB CONTENT REFLECTS USING NGS VERSION 18.0. UNCOMMANDED SHIFT TO 4L 1. Parking Maneuvers/Gear Lever Transitions: Symptoms noted during a lower speed uncommanded shift to 4L event include: ^ Front end binding or hopping while turning ^ Bind feel in drivetrain when backing up and/or turning Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 5247 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 5248 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case Inadvertent Shifts Control Module: All Technical Service Bulletins Transfer Case - Inadvertent Shifts Article No. 01-14-1 07/23/01 ^ ELECTRICAL - ELECTRONIC SHIFT ON THE FLY (ESOF) TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS ^ TRANSMISSION - TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS VEHICLES EQUIPPED WITH ELECTRONIC SHIFT ON THE FLY (ESOF) ONLY FORD: 1999 F-250 LD 1999-2001 EXPEDITION, F-150 LINCOLN: 1999-2001 NAVIGATOR ISSUE Some vehicles may exhibit inadvertent 4X4 Hi or Low shift events, 4X4 and/or Low Range indicator flashing or solid or vehicle stuck in 4L after uncommanded shift. This may be caused by the 4X4 shift motor. ACTION Install a YL1Z-7G360-AA shift motor on vehicles built before 12/99. The YL1Z-7G360-AA shift motor with a grey contact plate cover replaces the prior design F75Z-7G360-AA motor with a blue contact plate cover. Grey cover shift motors contain improved sense plate material and shift motor terminal upgrade. For vehicles already equipped with the latest style shift motor, refer to the following Service Procedure for details. SERVICE PROCEDURE For overall description and operation of the Electronic Shift On The Fly (ESOF) Transfer Case refer to Section 308-07 of the appropriate model year Workshop Manual. NOTE ALL DIAGNOSIS BY SYMPTOM SECTIONS HEREIN ARE WRITTEN ASSUMING THAT VEHICLE IS ALREADY EQUIPPED WITH THE LATEST STYLE SHIFT MOTOR. ALWAYS REPLACE SHIFT MOTOR AS A FIRST STEP IF CURRENT MOTOR IS PRIOR LEVEL WITH BLUE COVER. NOTE TO RESET THE GEM'S 4X4 MONITORING SOFTWARE, USE CLEAR DTC COMMAND IN THE NGS OR WOS TESTER (EVEN IF NO DTC'S ARE AVAILABLE) AND CYCLE IGNITION KEY ON-OFF-ON. RECORD ANY CONTINUOUS MEMORY CODES PRIOR TO CLEARING DTCs. NOTE AN UNCOMMANDED 4H OR 4L SHIFT DUE TO FALSE SHIFT MOTOR CONTACT PLATE SIGNAL MAY OR MAY NOT BE ACCOMPANIED BY SHIFT MOTOR DTC'S P1838, P1846, P1850, P1854, P1858, P1866, AND/OR P1867 STORED IN THE GEM DEPENDING ON WHETHER THE IGNITION KEY WAS CYCLED AFTER THE EVENT. NOTE CONTACT PLATE PIDS READ OPPOSITE OF 1999 OR EARLIER WORKSHOP MANUALS WHEN VIEWED WITH NGS RED CARD VERSIONS 15.0 OR LATER. THIS TSB CONTENT REFLECTS USING NGS VERSION 18.0. UNCOMMANDED SHIFT TO 4L 1. Parking Maneuvers/Gear Lever Transitions: Symptoms noted during a lower speed uncommanded shift to 4L event include: ^ Front end binding or hopping while turning ^ Bind feel in drivetrain when backing up and/or turning Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case Inadvertent Shifts > Page 5254 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case Inadvertent Shifts > Page 5255 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 5256 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Shift on the Fly Relay Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Shift on the Fly Relay > Page 5261 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Page 5262 Four Wheel Drive Selector Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Page 5263 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Description and Operation Overdrive Switch: Description and Operation The Transmission Control Switch (TCS) is a momentary contact switch that is located on the end of the transmission control selector lever. Pushing the TCS will either disengage or engage the overdrive function of the transmission. if the OVERDRIVE is disengaged, the word OFF will illuminate on the transmission control selector lever. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Description and Operation > Page 5269 Overdrive Switch: Service and Repair Removal 1. Remove the Transmission Control Switch (TCS). 1 Remove the TCS cover. 2 Remove the TCS. Installation 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > 4R70W Transmission Position Switch/Sensor: Specifications Digital Transmission Range Sensor Bolts 7-10 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > 4R70W > Page 5274 Transmission Position Switch/Sensor: Specifications Digital Transmission TR Sensor 8-10 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5275 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W Transmission Position Switch/Sensor: Service and Repair 4R70W Special Tools 1. Raise and support vehicle. 2. Disconnect the manual lever shift control cable. 3. Disconnect the digital TR electrical connector. 4. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. The old nut will not retain torque specification. Remove the manual control lever. 1 Remove the nut. 2 Remove the lever. 5. Loosen the digital TR sensor bolts. 6. NOTE: Manual shift lever must be in the neutral position. Use digital transmission range TR Sensor Alignment Tool, to align the digital TR sensor slots. The tool is designed to fit snug. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W > Page 5278 7. Tighten the bolts. 8. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual lever shaft outer nut. 9. With the manual lever in overdrive connect the shift lever control cable. 10. Install the digital TR sensor electrical connector. 11. Lower the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W > Page 5279 Transmission Position Switch/Sensor: Service and Repair 4R100 Special Tools Removal 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Disconnect the connector. 4. Disconnect the shift cable at the manual control lever. 5. Remove the digital Transmission Range (TR) sensor. 1 Remove the bolts. 2 Remove the digital Transmission Range (TR) sensor. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W > Page 5280 1. Install the digital Transmission Range (TR) sensor. 1 Install digital Transmission Range (TR) sensor. 2 Loosely install the bolts. 2. NOTE: Make sure that the manual control lever is in the neutral position. Install the Digital Transmission Range (TR) Sensor Alignment Tool. The tool is designed to fit snug. 3. Tighten the bolts. 4. Reconnect the shift cable at the manual control lever. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W > Page 5281 5. Reconnect the connector. 6. Lower the vehicle. 7. Reconnect the battery ground cable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Tools and Equipment > 4R70W Special Tool Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Tools and Equipment > 4R70W > Page 5284 Special Tool Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed Sensor Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed Sensor > Page 5289 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5290 Transmission Speed Sensor: Service and Repair Removal 1. Remove the drive shaft. 2. Remove the rear transmission mount nuts. 3. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the TSS and OSS sensors will occur. Remove the rear transmission mount. 1 Raise the transmission up off the rear crossmember support. 2 Remove the bolts. 3 Remove the rear transmission mount. 4. Lower the transmission to gain access to the Turbine Shaft Speed (TSS) sensor, and the Output Shaft Speed (OSS) sensor. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5291 5. Remove the Turbine Shaft Sensor (TSS). 1 Remove the bolt. 2 Remove the Turbine Shaft Sensor (TSS). 6. Remove the Output Shaft Speed (OSS) sensor. 1 Remove the bolt. 2 Remove the Output Shaft Speed (OSS) sensor. Installation 1. Install the Output Shaft Speed (OSS) sensor. 1 Lubricate the O-ring and install the Output Shaft Speed (OSS) sensor. 2 Install the bolt. 2. Install the Turbine Shaft Sensor (TSS). 1 Lubricate the O-ring and install the Turbine Shaft Sensor (TSS). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5292 2 Install the bolt. 3. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the sensors will occur. Install the rear transmission mount. 1 Raise the transmission up. 2 Install the rear transmission mount. 3 Install the bolts. 4. Lower the transmission on to the rear crossmember support. 5. Install the rear transmission mount nuts. 6. Install the drive shaft. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Output Shaft Speed Sensor Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Output Shaft Speed Sensor > Page 5298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 5299 Transmission Speed Sensor: Service and Repair Removal 1. Remove the drive shaft. 2. Remove the rear transmission mount nuts. 3. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the TSS and OSS sensors will occur. Remove the rear transmission mount. 1 Raise the transmission up off the rear crossmember support. 2 Remove the bolts. 3 Remove the rear transmission mount. 4. Lower the transmission to gain access to the Turbine Shaft Speed (TSS) sensor, and the Output Shaft Speed (OSS) sensor. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 5300 5. Remove the Turbine Shaft Sensor (TSS). 1 Remove the bolt. 2 Remove the Turbine Shaft Sensor (TSS). 6. Remove the Output Shaft Speed (OSS) sensor. 1 Remove the bolt. 2 Remove the Output Shaft Speed (OSS) sensor. Installation 1. Install the Output Shaft Speed (OSS) sensor. 1 Lubricate the O-ring and install the Output Shaft Speed (OSS) sensor. 2 Install the bolt. 2. Install the Turbine Shaft Sensor (TSS). 1 Lubricate the O-ring and install the Turbine Shaft Sensor (TSS). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 5301 2 Install the bolt. 3. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the sensors will occur. Install the rear transmission mount. 1 Raise the transmission up. 2 Install the rear transmission mount. 3 Install the bolts. 4. Lower the transmission on to the rear crossmember support. 5. Install the rear transmission mount nuts. 6. Install the drive shaft. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Specifications Four Wheel Drive Selector Switch: Specifications 4WD Indicator Switch .......................................................................................................................... ................................................ 41 Nm (30 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Specifications > Page 5306 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Specifications > Page 5307 Four Wheel Drive Selector Switch: Service and Repair Removal 1. Remove the center instrument panel trim plate. 2. Remove the shift range selector switch. 1 Remove the shift range selector switch knob. 2 Disconnect the shift range selector switch electrical connector. 3 Remove the two shift range selector switch bolts. 4 Remove the shift range selector switch. Installation 1. Install the shift range selector switch. 1 Position the shift range selector switch. 2 Install the bolts. 3 Install the electrical connector. 4 Install the knob. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Specifications > Page 5308 2. Install the center instrument panel trim plate. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Page 5312 Gear Sensor/Switch: Service and Repair Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the 4WD indicator switch. 1 Disconnect the 4WD indicator switch electrical connector. 2 Remove the 4WD indicator switch. Installation 1. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Specifications Speed Sensor: Specifications Output Shaft Speed Sensor 4 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Specifications > Page 5316 Speed Sensor: Service and Repair Removal 1. Remove the output shaft speed sensor connector. 2. Remove the bolt and the output shaft speed sensor. Installation 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 99-12-4 > Jun > 99 > A/T - 4R70W 4-3 Coastdown Clunk Noise On Deceleration PROM - Programmable Read Only Memory: Customer Interest A/T - 4R70W 4-3 Coastdown Clunk Noise On Deceleration Article No. 99-12-4 06/14/99 ^ NOISE - "CLUNKING" HEARD DURING 4-3 COASTDOWN WHILE DECELERATING FROM 48-32 KM/H (30-20 MPH) - VEHICLES WITH 5.4L ENGINE AND 4R70W TRANSMISSION ^ TRANSMISSION - 4R7OW - 4-3 COASTDOWN "CLUNK" WHILE DECELERATING FROM 48-32 KM/H (30-20 MPH) - VEHICLES WITH 5.4L ENGINE LIGHT TRUCK: 1999 F-150 CALIBRATION 9VZA-AC CALIBRATION, 9VZA-AD CALIBRATION WARNING THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE(S). PERFORMING THIS MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS. ISSUE A 4-3 coastdown "clunk" when decelerating from 48-32 km/h (30-20 mph) may occur on some vehicles. This may be caused by the Powertrain Control Module (PCM) calibration. ACTION Follow normal diagnostic procedures per the 1999 F-150 Workshop Manual and reprogram the PCM. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991204A Reprogram Powertrain 0.4 Hr. Control Module (PCM) DEALER CODING CONDITION BASIC PART NO. CODE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest: > 99-12-4 > Jun > 99 > A/T - 4R70W 4-3 Coastdown Clunk Noise On Deceleration > Page 5325 RECAL 42 OASIS CODES: 502000, 504000, 597997, 702200 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 5331 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 5332 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 99-12-4 > Jun > 99 > A/T - 4R70W 4-3 Coastdown Clunk Noise On Deceleration PROM - Programmable Read Only Memory: All Technical Service Bulletins A/T - 4R70W 4-3 Coastdown Clunk Noise On Deceleration Article No. 99-12-4 06/14/99 ^ NOISE - "CLUNKING" HEARD DURING 4-3 COASTDOWN WHILE DECELERATING FROM 48-32 KM/H (30-20 MPH) - VEHICLES WITH 5.4L ENGINE AND 4R70W TRANSMISSION ^ TRANSMISSION - 4R7OW - 4-3 COASTDOWN "CLUNK" WHILE DECELERATING FROM 48-32 KM/H (30-20 MPH) - VEHICLES WITH 5.4L ENGINE LIGHT TRUCK: 1999 F-150 CALIBRATION 9VZA-AC CALIBRATION, 9VZA-AD CALIBRATION WARNING THIS MODIFICATION IS AUTHORIZED ONLY FOR THE LISTED ENGINE(S). PERFORMING THIS MODIFICATION ON OTHER ENGINE CALIBRATIONS IS UNAUTHORIZED AND COULD CREATE LIABILITY UNDER APPLICABLE FEDERAL OR LOCAL LAWS. ISSUE A 4-3 coastdown "clunk" when decelerating from 48-32 km/h (30-20 mph) may occur on some vehicles. This may be caused by the Powertrain Control Module (PCM) calibration. ACTION Follow normal diagnostic procedures per the 1999 F-150 Workshop Manual and reprogram the PCM. Obtain an Authorized Modifications Decal (FPS 8262 - obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991204A Reprogram Powertrain 0.4 Hr. Control Module (PCM) DEALER CODING CONDITION BASIC PART NO. CODE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 99-12-4 > Jun > 99 > A/T - 4R70W 4-3 Coastdown Clunk Noise On Deceleration > Page 5337 RECAL 42 OASIS CODES: 502000, 504000, 597997, 702200 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls General PCM Programming Procedures TSB 04-24-14 12/13/04 FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria, Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer, F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport 2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS 1997-2005 Navigator 2003-2005 Aviator MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis, Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement. ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle concerns may be caused if proper programming procedures are not followed. ACTION Use the following procedure to reprogram PCMs. Verify repair after reprogramming. SERVICE PROCEDURE PRELIMINARY STEPS - Existing PCM Reprogramming Or PCM Replacement 1. Connect a battery charger to vehicle. 2. Use WDS if available. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 5343 a. Make sure WDS is docked or attached to vehicle battery supply. b. Verify WDS software is at the latest release level. 3. If there is a communication error, attempt to communicate with a different diagnostic scan tool, such as NGS, NGS+, VCM or another WDS. NOTE IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS, GROUNDS, AND CHECK VREF. PCM REPLACEMENT - STANDARD 1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able to communicate, to open a session, proceed to the Blank Path Programming procedure. 2. Install the new PCM. NOTE IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER. 3. Attempt to start the vehicle. 4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM. 5. Check for DTC P0602/P0605/P1639. a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure must be performed. Use the WDS session opened at Step 1. b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly set such as tire size, axle ratio, etc. 6. Check for DTC B2900. a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during this procedure. b. If DTC B2900 is not present proceed to Step 7. 7. Diagnose all other DTCs following normal diagnostic procedures. REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM Replacement 1. Verify all cables are properly connected. 2. Verify vehicle battery is at proper charge level. 3. Verify scan tool battery is at proper charge level. 4. Attempt reprogramming procedure again. 5. If reprogramming still does not complete properly, save current session, reboot WDS, open previous session, and attempt reprogramming again. 6. If reprogramming still does not complete or you are now unable to communicate with PCM, proceed to the Blank Path Programming procedure. BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not communicate, or if steps earlier in this TSB directed you to this procedure. 1. Verify powers and grounds to PCM by loading and voltage drop testing circuits. 2. Follow Pin Point Tests to verify network integrity. NOTE IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT TURN THE KEY ON WHEN WDS IS Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: > 04-24-14 > Dec > 04 > Engine Controls - General PCM Programming Procedures > Page 5344 INITIALLY CONNECTED TO THE DLC. 3. Connect WDS to vehicle. 4. Select "16 pin", select "All others, except those below", press TICK. 5. Screen shows installation of cable, press TICK. 6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK. 7. Screen shows progress bar, then screen tells you "No communication can be established with the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press TICK. 8. Screen shows to turn ignition ON. Turn ignition on, press TICK. 9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN from a list of previous sessions. Press TICK. 10. When previous sessions are shown select "None of the above". 11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK. 12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed above. Press TICK. 13. Follow and answer correctly all remaining screens. 14. Once PCM is reprogrammed communication should be reestablished and PATS system can be reset (if necessary) as per Section 419-01 of the Workshop Manual. WARRANTY STATUS: Information Only Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair Pressure Regulating Solenoid: Service and Repair Electronic Pressure Control (EPC) Solenoid Removal 1. Remove the manual control lever. 2. CAUTION: Do not pull on the plastic lead frame. This may cause damage to the connector ends. Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame from the solenoids. Disconnect the molded lead frame from the solenoids. 1 Disconnect the shift solenoid SSA and SSB. 2 Disconnect the Torque Converter Clutch (TCC). 3 Disconnect the Electronic Pressure Control (EPC) solenoid. 4 Disconnect the bulkhead inter-connector. 3. Remove the EPC solenoid. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Page 5351 1. Install the EPC solenoid. 2. Connect the molded lead frame to the solenoids. - Connect the bulkhead inter-connector. - Connect the Electronic Pressure Control (EPC) solenoid. - Connect the Torque Converter Clutch (TCC). - Connect the shift solenoid SSA and SSB. 3. Install the manual control lever. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications Shift Interlock Solenoid: Specifications Shift Lock Actuator Bolts 7-11 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 5355 Shift Interlock Solenoid: Service and Repair Removal 1. Remove the steering column assembly. 2. Remove the insert plate and shift lock actuator. 1 Remove the bolts. 2 Remove the insert plate and shift lock actuator. 3. NOTE: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to be replaced in the field. Remove the insert plate from the shift lock actuator. Remove and discard the shift lock actuator clip. Installation 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair Shift Solenoid: Service and Repair Refer to Valve Body for service procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications TCC Solenoid Bolt 9-11 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications Transfer Case Actuator: Specifications Shift Motor Bolts .................................................................................................................................. ............................................. 10 Nm (89 inch lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 5366 Transfer Case Actuator: Service and Repair Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Disconnect the shift motor electrical connector. 3. Remove the coil wire from the electric shift motor electrical connector. 1 Remove the wire connector spacer. 2 Remove the coil wire and pin. Use correct electrical connector pin remover. 4. Remove the transfer case shift motor. 1 Remove the bolts. 2 Remove the transfer case shift motor. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 5367 1. Install the transfer case shift motor. 1 Position the transfer case shift motor. 2 Install the bolts. 2. Install the coil wire into the transfer case shift motor electrical connector. 1 Install the coil wire and pin. 2 Install the wire connector spacer. 3. Connect the transfer case shift motor electrical connector. 4. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair Pressure Regulating Solenoid: Service and Repair Electronic Pressure Control (EPC) Solenoid Removal 1. Remove the manual control lever. 2. CAUTION: Do not pull on the plastic lead frame. This may cause damage to the connector ends. Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame from the solenoids. Disconnect the molded lead frame from the solenoids. 1 Disconnect the shift solenoid SSA and SSB. 2 Disconnect the Torque Converter Clutch (TCC). 3 Disconnect the Electronic Pressure Control (EPC) solenoid. 4 Disconnect the bulkhead inter-connector. 3. Remove the EPC solenoid. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Page 5373 1. Install the EPC solenoid. 2. Connect the molded lead frame to the solenoids. - Connect the bulkhead inter-connector. - Connect the Electronic Pressure Control (EPC) solenoid. - Connect the Torque Converter Clutch (TCC). - Connect the shift solenoid SSA and SSB. 3. Install the manual control lever. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Specifications Shift Interlock Solenoid: Specifications Shift Lock Actuator Bolts 7-11 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 5377 Shift Interlock Solenoid: Service and Repair Removal 1. Remove the steering column assembly. 2. Remove the insert plate and shift lock actuator. 1 Remove the bolts. 2 Remove the insert plate and shift lock actuator. 3. NOTE: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to be replaced in the field. Remove the insert plate from the shift lock actuator. Remove and discard the shift lock actuator clip. Installation 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Service and Repair Shift Solenoid: Service and Repair Refer to Valve Body for service procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications TCC Solenoid Bolt 9-11 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Customer Interest for Accumulator: > 99-18-5 > Sep > 99 > A/T 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift Accumulator: Customer Interest A/T - 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift Article No. 99-18-5 09/06/99 ^ TRANSMISSION CONTROL INDICATOR LAMP (TCIL) - TCIL ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) P0782 STORED IN MEMORY - VEHICLES BUILT BETWEEN 3/15/1997 AND 12/31/1998 AND WITH 4R70W TRANSMISSION ^ TRANSMISSION - 4R70W - DELAYED OR NO 2-3 UPSHIFT - VEHICLES BUILT BETWEEN 3/15/1997 AND 12/31/1998 FORD: 1997-1999 CROWN VICTORIA, MUSTANG, ECONOLINE, EXPEDITION, EXPLORER, F-150, F-250 LD LINCOLN: 1997-1998 MARK VIII 1997-1999 TOWN CAR MERCURY: 1997-1999 GRAND MARQUIS, MOUNTAINEER This TSB article is being republished in its entirety to revise the Service Procedure. ISSUE A perceived 2-3 delayed upshift, primarily when the transmission is cold, may be evident on some vehicles. The Powertrain Control Module (PCM) strategy is designed to delay shifts in some vehicles when Transmission Fluid Temperature (TFT) is below approximately 21°C (70°F) for taster heater warmup. The 2-3 shift may be delayed approximately 14-24 km/h (9-15 mph) when compared to the shift speed charts listed in the appropriate Service or Workshop Manual. A leaking 2-3 accumulator may cause Diagnostic Trouble Code (DTC) P0782. ACTION Verify if delayed upshift is normal cold shift scheduling or a possible leak past the large diameter 2-3 accumulator seal. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Using New Generation Star (NGS) Tester, perform all self tests and record DTCs. 2. Monitor rpm, and gear command Parameter Identification Displays (PIDs) with the NGS Tester during the 2-3 shift. 3. If engine rpm decreases within 1-2 seconds after the gear command has changed on the NGS Tester, then vehicle has upshifted properly and no repair is necessary. If engine rpm does not drop within 1-2 seconds, continue to Step 4. 4. If engine rpm does not drop when the PCM commands third gear, then replace the 2-3 accumulator piston using the revised Accumulator Piston (F7AZ-7H292-AB). Refer to the appropriate Service or Workshop Manual for replacement procedure. PART NUMBER PART NAME F7AZ-7H292-AB Accumulator Piston OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-1-3 WARRANTY STATUS: Eligible Under the Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991805A Replace Accumulator 1.8 Hrs. Piston Per Service Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > Customer Interest for Accumulator: > 99-18-5 > Sep > 99 > A/T 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift > Page 5392 Procedure (Includes Diagnosis) 991805B Diagnosis Only (Do Not 0.8 Hr. Use With Operation A) DEALER CODING CONDITION BASIC PART NO CODE 7H292 42 OASIS CODES: 501000, 504000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator: > 99-18-5 > Sep > 99 > A/T - 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift Accumulator: All Technical Service Bulletins A/T - 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift Article No. 99-18-5 09/06/99 ^ TRANSMISSION CONTROL INDICATOR LAMP (TCIL) - TCIL ILLUMINATED WITH DIAGNOSTIC TROUBLE CODE (DTC) P0782 STORED IN MEMORY - VEHICLES BUILT BETWEEN 3/15/1997 AND 12/31/1998 AND WITH 4R70W TRANSMISSION ^ TRANSMISSION - 4R70W - DELAYED OR NO 2-3 UPSHIFT - VEHICLES BUILT BETWEEN 3/15/1997 AND 12/31/1998 FORD: 1997-1999 CROWN VICTORIA, MUSTANG, ECONOLINE, EXPEDITION, EXPLORER, F-150, F-250 LD LINCOLN: 1997-1998 MARK VIII 1997-1999 TOWN CAR MERCURY: 1997-1999 GRAND MARQUIS, MOUNTAINEER This TSB article is being republished in its entirety to revise the Service Procedure. ISSUE A perceived 2-3 delayed upshift, primarily when the transmission is cold, may be evident on some vehicles. The Powertrain Control Module (PCM) strategy is designed to delay shifts in some vehicles when Transmission Fluid Temperature (TFT) is below approximately 21°C (70°F) for taster heater warmup. The 2-3 shift may be delayed approximately 14-24 km/h (9-15 mph) when compared to the shift speed charts listed in the appropriate Service or Workshop Manual. A leaking 2-3 accumulator may cause Diagnostic Trouble Code (DTC) P0782. ACTION Verify if delayed upshift is normal cold shift scheduling or a possible leak past the large diameter 2-3 accumulator seal. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Using New Generation Star (NGS) Tester, perform all self tests and record DTCs. 2. Monitor rpm, and gear command Parameter Identification Displays (PIDs) with the NGS Tester during the 2-3 shift. 3. If engine rpm decreases within 1-2 seconds after the gear command has changed on the NGS Tester, then vehicle has upshifted properly and no repair is necessary. If engine rpm does not drop within 1-2 seconds, continue to Step 4. 4. If engine rpm does not drop when the PCM commands third gear, then replace the 2-3 accumulator piston using the revised Accumulator Piston (F7AZ-7H292-AB). Refer to the appropriate Service or Workshop Manual for replacement procedure. PART NUMBER PART NAME F7AZ-7H292-AB Accumulator Piston OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-1-3 WARRANTY STATUS: Eligible Under the Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991805A Replace Accumulator 1.8 Hrs. Piston Per Service Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Accumulator: > 99-18-5 > Sep > 99 > A/T - 4R70W TCIL ON/Code P0782/Delayed/No 2-3 Upshift > Page 5398 Procedure (Includes Diagnosis) 991805B Diagnosis Only (Do Not 0.8 Hr. Use With Operation A) DEALER CODING CONDITION BASIC PART NO CODE 7H292 42 OASIS CODES: 501000, 504000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > 4R70W Accumulator: Service and Repair 4R70W 1-2 Accumulator Special Tools Removal 1. Use (A) Servo Piston Remover Replacer to compress the 1-2 accumulator cover and remove the (B) accumulator piston retaining ring. 2. NOTE: Note the location of the 1-2 accumulator springs for reference during assembly. 1 Remove the 1-2 accumulator cover. 2 Remove the lower 1-2 accumulator spring. 3 Remove the accumulator piston. 4 Remove the upper 1-2 accumulator spring. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > 4R70W > Page 5401 1. Install the 1-2 accumulator. 1 Install the 1-2 accumulator upper spring. 2 Install the accumulator piston. 3 Install the 1-2 accumulator lower spring. 4 Install the cover and seal assembly. 2. Use (A) Servo Piston Remover Replacer to install the (B) accumulator piston retaining ring. 2-3 Accumulator Removal 1. Remove the main control valve body. 2. Remove the 2-3 accumulator piston retainer. 3. Remove the accumulator piston and spring. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > 4R70W > Page 5402 Installation 1. Install the 2-3 accumulator assembly. 1 Install the accumulator piston. 2 Install the accumulator piston spring. 3 Install the accumulator spring retainer. 2. Install the main control valve body. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > 4R70W > Page 5403 Accumulator: Service and Repair 4R100 Refer to Valve Body for service procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > Page 5404 Special Tool Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Application and ID > 4R70W Band: Application and ID 4R70W Part 1 Of 2 Part 2 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Application and ID > 4R70W > Page 5409 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > 4R70W Band Apply Servo: Service and Repair 4R70W Overderive Servo Special Tools Removal 1. Remove the main control valve body. 2. NOTE: If tool is not available, extreme care must be taken. Spring pressure will force overdrive servo piston assembly out of case. Case bore damage may result from trying to pry on overdrive servo internal retaining ring. Use (A) Servo Piston Remover/Replacer to compress the servo spring then remove the (B) overdrive servo retaining ring. 3. Remove the (A) overdrive servo piston and the (B) overdrive servo piston return spring. Installation 1. Install the overdrive servo piston assembly. 1 Install the overdrive servo piston return spring. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > 4R70W > Page 5414 2 Install the overdrive servo piston assembly. 2. Use (A) Servo Piston Remover/Replacer Tool to install the (B) overdrive servo piston retaining ring. 3. Install the main control valve body. Reverse Servo Assembly Special Tools Removal 1. Remove the main control valve body. 2. Use the Servo Piston Remover/Replacer to remove the reverse band servo retaining ring. 1 Compress the servo spring. 2 Remove the reverse band servo retaining ring. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > 4R70W > Page 5415 3. NOTE: The length of the rod attached to the piston is graded for three different lengths. Therefore, they should not be installed in any transmission other than the transmission from which they were removed. Remove the (A) reverse band servo cover, (B) reverse band servo piston and rod and (C) reverse band servo spring. Installation NOTE: This is not an ordinary installation procedure and does not compensate for band wear. 1. NOTE: Lubricate the reverse piston seal to facilitate assembly and prevent damage to the seal. Install the reverse servo piston and return spring. Do not install the piston cover. 2. Install the Servo Piston Selection Tool and tighten the band apply bolt. 3. Attach the Dial Indicator With Bracketry. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > 4R70W > Page 5416 - Position the indicator stem on the flat portion of the reverse servo piston and zero the dial indicator. 4. Loosen the bolt until the piston stops against the tool. 5. Verify the amount of piston travel on the dial indicator is within specification. 6. If piston travel is not within specification, select the proper servo assembly (A) one groove, (B) two groove, or (C) three groove, to bring the servo piston travel within specification. 7. Remove the dial indicator and servo selection tool. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > 4R70W > Page 5417 8. Install the proper servo piston assembly spring and the reverse servo piston cover and seal. 9. Use the Servo Piston Remover/Replacer to install the reverse servo retaining ring. 1 Compress the servo spring. 2 Install the reverse band servo retaining ring. 10. Install the main control valve body. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > 4R70W > Page 5418 Band Apply Servo: Service and Repair 4R100 Removal 1. Remove the main control valve body. 2. WARNING: The intermediate servo is under spring pressure, care should be taken when removing it. It could cause bodily harm. NOTE: Gently tap on the servo cover with a rubber mallet to compress and allow servo assembly to pop up. Remove the intermediate servo. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > 4R70W > Page 5419 1. NOTE: Lubricate the servo seal with clean transmission fluid. Install the intermediate band servo. 2. Install the main control valve body. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Page 5420 Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > 4R70W Clutch: Specifications 4R70W Clearance 1.01-1.524 mm Snap Ring Thickness 1.524-1.625 mm 1.880-1.981 mm 2.235-2.337 mm 2.591-2.692 mm Clearance 1.5748-2.159 mm Snap Ring Thickness 1.270-1.372 mm 1.625-1.727 mm 1.981-2.083 mm 2.337-2.438 mm Forward Clutch Forward Clutch Pack Clearance: 1.27-2.38 mm (0.050-0.094 inch) Snap Ring Thickness: 1.524-1.625 mm (0.060-0.064 inch) 1.880-1.981 mm (0.074-0.078 inch) 2.235-2.337 mm (0.088-0.092 inch) 2.591-2.692 mm (0.102-0.106 inch) Clearance 41.7322-42.5958 mm Snap Ring Thickness 1.702-1.803 mm 1.956-2.057 mm 2.210-2.311 mm 2.464-2.565 mm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > 4R70W > Page 5425 Clutch: Specifications 4R100 Coast Clutch Coast Clutch Steel .................................................................................................................................................... ............................................................................. 2 Friction ................................................................ ............................................................................................................................................................. 2 Clearance ......................................................................................................................................... ............................................................ 1.27-0.76 mm Snap Ring Thickness: 0.089-0.085 mm 0.073-0.069 mm 0.057-0.053 mm Steel 5 ct Plus a steel wave cushion spring installed between the reverse clutch piston and a steel separator plate. Friction 5 ct Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Specifications > 4R70W > Page 5426 Snap Ring Thickness 0.074-0.078 mm A non-selective snap ring. Steel Discs 2 ct Friction Discs 2 ct Clearance 1.33-0.68 mm Steel 4 ct Friction 4 ct Clearance 2.06-1.14 mm Forward Clutch Forward Clutch Steel [c] ................................................................................................................................................ ............................................................................ 4 Friction ................................................................. ............................................................................................................................................................ 4 Clearance ......................................................................................................................................... ............................................................ 1.04-0.76 mm Snap Ring Thickness: 0.056-0.060 mm 0.074-0.078 mm 0.092-0.096 mm 0.110-0.114 mm 0.128-0.132 mm [c] Plus a steel wave cushion spring installed between the front pressure plate and a steel separator plate. Steel Discs 2 ct Plus one apply plate. Friction Discs 3 ct Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Diagrams > 4R70W Clutch: Diagrams 4R70W Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Diagrams > 4R70W > Page 5429 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Diagrams > 4R70W > Page 5430 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Diagrams > 4R70W > Page 5431 Clutch: Diagrams 4R100 Part 2 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Diagrams > 4R70W > Page 5432 Part 2 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Diagrams > 4R70W > Page 5433 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Diagrams > 4R70W > Page 5434 Part 2 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Tools and Equipment > 4R70W Clutch: Tools and Equipment 4R70W Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Tools and Equipment > 4R70W > Page 5437 Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Tools and Equipment > 4R70W > Page 5438 Clutch: Tools and Equipment 4R100 Special Tools Special Tools Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Tools and Equipment > 4R70W > Page 5439 Special Tools Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission Dipstick - Dipstick Tube > Component Information > Service and Repair > 4R70W Automatic Transmission Dipstick - Dipstick Tube: Service and Repair 4R70W Removal 1. Remove the transmission fluid filler tube bolt from the side of the RH cylinder head. 2. Remove the fluid filler tube. Installation 1. Follow the removal procedure in reverse order. 2. Install the transmission fluid tube bolt to the side of the RH cylinder head. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission Dipstick - Dipstick Tube > Component Information > Service and Repair > 4R70W > Page 5444 Automatic Transmission Dipstick - Dipstick Tube: Service and Repair 4R100 Removal 1. Remove the fluid level indicator. 2. Disconnect the battery ground cable. 3. Raise the vehicle on a hoist. 4. Remove the bolt. 5. Remove the oil filler tube. Installation 1. NOTE: Coat the O-ring at the bottom of the oil filler tube with transmission fluid. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission Dipstick - Dipstick Tube > Component Information > Service and Repair > 4R70W > Page 5445 Install the oil filler tube. 2. Install the bolt. 3. Lower the vehicle. 4. Install the fluid level indicator. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage Fluid - A/T: Technical Service Bulletins A/T - Mercon V ATF Usage TSB 06-14-4 07/24/06 MERCON ATF IS BEING REPLACED BY MERCON V ATF AS A SERVICE FLUID. FORD: 1980-1997 Crown Victoria 1981-1997 Mustang, Thunderbird 1981-2003 Escort 1986-1993 Festiva 1986-1997 Taurus 1989-1997 Probe 1994-1997 Aspire 1995-2000 Contour 1980-1996 Bronco 1981-2003 F-150 1981-2004 E-Series, F-Super Duty 1983-1996 Ranger 1986-1996 Aerostar 1991-1997 Explorer 1993-2004 F-53 Motorhome Chassis 1995-1998 Windstar 1997-2004 Expedition 2000-2005 Excursion 2001-2007 Escape 1987-2000 F-B-Series 2000-2007 F-650, F-750 LINCOLN: 1980-1997 Town Car 1981-1997 Continental 1993-1997 Mark VIII 1998-2004 Navigator 2002-2003 Blackwood MERCURY: 1980-1997 Grand Marquis 1981-1997 Cougar 1986-1997 Sable 1987-1999 Tracer 1995-2000 Mystique 1999-2002 Cougar 1993-2002 Villager 1997 Mountaineer 2005-2007 Mariner MERKUR: 1985-1989 XR4TI This article supersedes TSB 01-15-7 to update the vehicle application chart. ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid. ACTION Beginning immediately all automatic transmission / transaxle applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will only continue for however long it takes to deplete what remains in inventory. SERVICE PROCEDURE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage > Page 5450 Service automatic transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V For proper fluid application on current and past model vehicles equipped with automatic transmissions I transaxles refer to the fluid usage chart. (Figure 1) CAUTION AUTOMATIC TRANSMISSIONS / TRANSAXLES THAT REQUIRE MERCON® V SHOULD STILL ONLY USE MERCON(R) V OR DUAL USAGE FLUID LABELED MERCON(R) / MERCON(R) V. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage > Page 5451 CAUTION MERCON(R) SP, MOTORCRAFT PREMIUM AUTOMATIC TRANSMISSION FLUID AND MOTORCRAFT M5 ATFS ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS RECOMMENDING THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR TRANSMISSION DAMAGE. CAUTION THE FUNCTIONAL CHARACTERISTICS OF FLUIDS FOR CVT TRANSMISSIONS ARE VERY DIFFERENT THAN THOSE OF OTHER AUTOMATIC TRANSMISSION FLUIDS (ATFS). USE OF A FLUID OTHER THAN MOTORCRAFT CONTINUOUSLY VARIABLE CHAIN TYPE TRANSMISSION FLUID OR ONE LABELED AS MEETING MERCON(R) C WILL CAUSE FUNCTIONALITY CONCERNS AND INTERNAL TRANSMISSION DAMAGE. CAUTION DO NOT USE AUTOMATIC TRANSMISSION FLUID SUPPLEMENTS, ADDITIVES, TREATMENTS OR CLEANING AGENTS. Parts Block WARRANTY STATUS: Information Only Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications A/T Fluid 4R100 .................................................................................................................................................. .......................................................... 15.5L (16.4 Qt) 4R70W ................................................................................................................................................. ......................................................... 13.1L (13.8 Qt) NOTE: Approximate dry fill capacity. Fluid level should be set by indicator on dipstick's normal operating range. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 5454 Fluid - A/T: Fluid Type Specifications MERCON(R) automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4. Automatic (4R70W) ............................................................................................ ...................................................................................... MERCON V ATF Automatic (4R100) ................ MERCON(R) automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5455 Fluid - A/T: Diagrams PARK Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5456 PARK Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5457 PARK Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5458 PARK Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5459 2 ND GEAR Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5460 2 ND GEAR Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5461 TCC RELEASE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5462 TCC RELEASE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5463 LINE/SRV PRESSURE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5464 PARK NON-PTO Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5465 PARK NON-PTO Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5466 1ST GEAR NON-PTO Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5467 2ND GEAR NON-PTO Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5468 3RD GEAR NON-PTO Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5469 4TH GEAR NON-PTO Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5470 MANUAL 3RD GEAR NON-PTO Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5471 MANUAL 2ND GEAR NON-PTO Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5472 MANUAL 1ST GEAR NON-PTO Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5473 Fluid - A/T: Service Precautions DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission damage may occur. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 5474 Fluid - A/T: Description and Operation 1. Normal maintenance requires periodic automatic transmission fluid changes. If a major service, such as a clutch, band, bearing, etc., is required, the automatic transmission fluid will also have to be removed for service. At this time, the torque converter, transmission cooler, cooler inlet tube and cooler tube must be thoroughly flushed to remove any dirt. When used under continuous or severe conditions, the transmission and torque converter should be drained and refilled with fluid. Normal Maintenance No recommended changes - Special Operating Conditions Change fluid at 48,000 kin (30,000 miles) 2. CAUTION: Use of a fluid other than specified could result in transmission malfunction and/or failure. Refer to the vehicle certification label affixed to the LH front door lock face panel or door pillar for the transmission code. 3. When filling a dry transmission and torque converter, refer to Specification. Check the fluid level. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 4R70W Fluid - A/T: Service and Repair 4R70W Removal 1. Raise and support vehicle. 2. Place a drain pan under the transmission fluid pan. 3. Drain transmission fluid, - Loosen the transmission fluid pan bolts and allow fluid to drain. After fluid is drained, remove the bolts. 4. Remove the (A) transmission fluid pan and (B) transmission fluid pan gasket. - Replace transmission fluid pan gasket as necessary. 5. Remove torque converter housing plug. 6. Remove the torque converter drain plug and drain the torque converter. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 4R70W > Page 5477 - Rotate the crankshaft to access the drain plug. 7. Clean and inspect the (A) transmission fluid pan, (B) transmission fluid pan gasket and (C) magnet. 8. Flush the fluid cooler, and fluid cooler lines. 9. Flush the torque converter. Installation 1. NOTE: A new torque converter drain plug must be used. Install the torque converter drain plug. 2. Install torque converter housing plug. 3. CAUTION: If installing a new filter, and the seal remains in the main control bore, carefully use a small screwdriver to remove the seal. Use care not to damage the main control bore. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 4R70W > Page 5478 NOTE: If the transmission is being repaired for a contamination-related failure, use a new filter and seal. The filter may be reused if no excessive contamination is present. Replace fluid filter and seal as required. 4. Position the (B) pan magnet into the (A) transmission fluid pan. 5. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage; if not damaged, the gasket should be reused. Install the transmission fluid pan and gasket. 1 Install the transmission fluid pan gasket. 2 Install the transmission fluid pan. 6. Install the bolts. 7. Lower the vehicle. 8. NOTE: When filling a dry transmission and torque converter start with a minimum of 4.7 liters (5 quarts). Fill transmission to proper fluid level. Use MERCON V Automatic Transmission Fluid or equivalent meeting MERCON V specification XT-5-QM. MERCON(R) automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 4R70W > Page 5479 Fluid - A/T: Service and Repair 4R100 Removal 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Remove the drain plug to allow the fluid to drain. 4. CAUTION: When replacing the transmission fluid and filter and seal assembly, the torque converter should be drained. The transmission cooler, cooler lines, and cooler bypass valve must be thoroughly flushed to remove any contamination. NOTE: Do not discard the gasket unless damaged. This is a reusable gasket. Remove the transmission fluid pan and gasket. 1 Loosen, but do not remove the bolts. 2 Remove the front and side bolts. 3 Lower the front of the fluid pan and allow the fluid to drain. 4 Remove the remaining fluid pan bolts and the fluid pan. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 4R70W > Page 5480 5. NOTE: After removal, discard the filter and seal assembly. Remove the filter and seal assembly by carefully pulling and rotating the filter as necessary. 6. CAUTION: Be careful not to scratch or damage the aluminum bore. The new seal may leak and damage to the case will result. If the seal remains in the pump bore, remove it carefully with a small screwdriver so as not to scratch or damage the aluminum bore. 7. Remove the torque converter drain plug cover. 8. Remove the torque converter drain plug. 9. NOTE: If equipped with a radiator in-tank transmission fluid cooler, auxiliary cooler, and an Oil-To-Air (OTA) cooler, the in-tank fluid cooler and the auxiliary cooler will need to be flushed, and the OTA will need to be replaced. NOTE: If performing the drain and refill procedure for maintenance the oil to air oil cooler will not need to be replaced. If performing an Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 4R70W > Page 5481 overhaul the Oil-To-Air Cooler (OTA) will be required to be replaced. Thoroughly flush the cooler lines, fluid coolers, and the cooler bypass valve. Installation 1. After the torque converter has drained, install the drain plug. 2. Install the torque converter drain plug cover. 3. NOTE: Prior to installation, lightly lubricate the seal with clean Motorcraft MERCON Multi-Purpose (ATF) Transmission Fluid XT-2-QDX or equivalent Meeting MERCON specification. MERCON(R) automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4. Press a new fluid filter and seal assembly into the pump bore until seated. 4. CAUTION: Mixing (A) 4x2-style and (B) 4x4-style transmission fluid filters and transmission pan assembly components can cause Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > 4R70W > Page 5482 transmission damage. Install filter assembly and transmission pan. 5. NOTE: Transmission pan gasket is reusable unless damaged. NOTE: Apply a light coat of petroleum jelly to hold the gasket to the fluid pan. Position the (A) gasket onto the cleaned fluid pan. Make sure the (B) magnet is positioned over the dimple in the fluid pan. 6. Install the fluid pan. 1 Position the fluid pan. 2 Install the bolts. 7. Lower the vehicle. 8. Reconnect the battery ground cable. 9. CAUTION: Use only Motorcraft MERCON Multi-Purpose (ATF) Transmission Fluid XT-2-QDX or equivalent Meeting MERCON specification. The use of any other fluids can result in the transmission failing to operate in a normal manner or failure. Refill the transmission. Add 6.2 liters (6.5 quarts) of Motorcraft MERCON Multi-Purpose(ATF) Transmission Fluid XT-2-QDX or equivalent Meeting MERCON specification. transmission fluid to the transmission through the fluid filler tube. - Start the engine. Move the transmission range selector lever through all the gear ranges and allow to engage before moving to the next gear. - Check and adjust the transmission fluid, in 0.24 liter (0.5 pint) increments, to the proper level (cross-hatched area of the fluid level indicator at normal operating temperature. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Service and Repair > Page 5483 Special Tool Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications > 4R70W Fluid Line/Hose: Specifications Fluid Cooler Line Case Fittings 24-30 Nm Cooler Tube Nut to Case Fitting 13-22 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Specifications > 4R70W > Page 5488 Fluid Line/Hose: Specifications Cooler Line Fitting to Case Fitting Front CBV 20 Nm Rear CBV 24 Nm Cooler Line Case Fitting Front CBV 30 Nm Rear CBV 36 Nm Connector-Radiator Nipple 22-31 Nm Cooler Line Fitting to Radiator 24-30 Nm Auxiliary Cooler Tube 11-14 Nm Auxiliary Cooler Tube 22-30 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 4R70W Fluid Line/Hose: Service and Repair 4R70W Removal 1. Raise and support the vehicle. 2. Remove the front skid plate. 1 Remove the bolts. 2 Remove the front skid plate. 3. Remove the lower air deflector. 1 Remove the bolts. 2 Remove the lower air dam. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 4R70W > Page 5491 4. NOTE: Note the differences in tube routing between vehicles with a transmission auxiliary fluid cooler and vehicles without an auxiliary fluid cooler. Remove the damaged transmission fluid cooler tube. 1 Remove the three clips. 2 Disconnect the tube fittings. 3 Remove the transmission fluid cooler tube. Installation 1. NOTE: Note the differences in tube routing between vehicles with a transmission auxiliary fluid cooler and vehicles without an auxiliary fluid cooler. Install the transmission fluid cooler tube. 1 Position the transmission fluid cooler tube. 2 Connect the tube fittings. 3 Install the clips. 2. Install the transmission fluid cooler tubes. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 4R70W > Page 5492 3. Install the lower air deflector. 1 Position the deflector. 2 Install the bolts. 4. Install the front skid plate. - Install the bolts. 5. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. 6. Fill transmission fluid to the proper level and inspect for leaks. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 4R70W > Page 5493 Fluid Line/Hose: Service and Repair 4R100 Removal 1. Raise and support the vehicle. 2. Remove the front skid plate. 1 Remove the bolts. 2 Remove the front skid plate. 3. Remove the lower air deflector. 1 Remove the bolts. 2 Remove the lower air dam. 4. Remove the damaged transmission fluid cooler tube. 1 Remove the three clips. 2 Disconnect the tube fittings. 3 Remove the transmission fluid cooler tube. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 4R70W > Page 5494 5. NOTE: Note the differences in tube routing between vehicles with a transmission auxiliary fluid cooler and vehicles without an auxiliary fluid cooler. Remove the damaged transmission fluid cooler tube. 1 Remove the three clips. 2 Disconnect the tube fittings. 3 Remove the transmission fluid cooler tube. Installation 1. NOTE: Note the differences in tube routing between vehicles with a transmission auxiliary fluid cooler and vehicles without an auxiliary fluid cooler. Install the transmission fluid cooler tubes. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > 4R70W > Page 5495 1 Position the transmission fluid cooler tube. 2 Connect the tube fittings. 3 Install the clips. 2. Install the transmission fluid cooler tube. 3. Install the lower air deflector. 1 Position the deflector. 2 Install the bolts. 4. Install the front skid plate. - Install the bolts. 5. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. 6. Fill transmission fluid to the proper level and inspect for leaks. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > 4R70W Fluid Pan: Specifications Transmission Fluid Pan Bolts 12-15 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > 4R70W > Page 5500 Fluid Pan: Specifications Transmission Pan 14-16 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 5501 Fluid Pan: Service and Repair Removal 1. Raise and support vehicle. 2. Place a drain pan under the transmission fluid pan. 3. Drain the transmission fluid. - Loosen the bolts and allow the fluid to drain. After the fluid is drained remove the bolts. 4. Remove the (A) transmission fluid pan and (B) transmission fluid pan gasket. 5. Pull down evenly and remove the transmission fluid filter, seal and filter kit. 6. Remove torque converter housing plug. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 5502 7. Remove the torque converter drain plug and drain the torque converter. - Rotate the crankshaft to access the drain plug. 8. Clean and inspect the (A)transmission fluid pan, (B) transmission fluid pan gasket and (C) magnet. 9. Flush the fluid cooler and cooler lines. 10. Flush the torque converter. Installation 1. NOTE: A new torque converter drain plug must be used. Install the torque converter drain plug. 2. Install torque converter housing plug. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 5503 3. CAUTION: If installing a new filter, and the seal remains in the main control bore, carefully use a small screwdriver to remove the seal. Use care not to damage the main control bore. NOTE: If transmission is being serviced for a contamination-related failure, use a new filter and seal. The filter may be reused if no excessive contamination is present. Replace fluid filter and seal as required. 4. Position the (B) pan magnet into the (A) transmission fluid pan. 5. NOTE: The transmission fluid pan gasket is reusable, clean and inspect for damage; if not damaged, the gasket should be reused. Install the transmission fluid pan. 1 Position the transmission fluid pan gasket. 2 Position the transmission fluid pan. 6. Install the bolts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 5504 7. Lower the vehicle. 8. NOTE: When filling a dry transmission and converter start with a minimum of 4.7 liters (5 quarts). Fill transmission to proper fluid level. Use MERCON V Automatic Transmission Fluid or equivalent meeting MERCON V specification XT-5-QM. MERCON(R) automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications > 4R70W Fluid Pump: Specifications Front Pump Bolts 20-26 Nm Front Pump Support Bolts 20-26 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Specifications > 4R70W > Page 5509 Fluid Pump: Specifications Control Assembly to Pump Body Bolts 24-31 Nm Pump Body to Case 24-31 Nm Stator to Support to Pump Body Bolts 27 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Diagrams > 4R70W Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Diagrams > 4R70W > Page 5512 Fluid Pump: Diagrams 4R100 Part 1 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Diagrams > 4R70W > Page 5513 Part 2 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > 4R100 Fluid Pump: Service and Repair 4R100 Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > 4R100 > Page 5516 Part 1 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > 4R100 > Page 5517 Part 2 Of 2 Disassembly CAUTION: The pump assembly is vehicle-dependent. Failure to use the correct pump may cause transmission assembly damage. 1. NOTE: Inspect and replace the front pump seal, if damaged. Using the (A) Seal Remover and the (B) Impact Slide Hammer, remove the (C) front pump seal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > 4R100 > Page 5518 2. Remove the front pump stator support seal. 3. Remove the 2 Teflon coast clutch seals. 4. Remove the pump outer diameter square-cut front pump seal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > 4R100 > Page 5519 5. CAUTION: Do not reuse the orifice cup plug or spring and stop assembly. Failure to replace these parts may cause repeat repairs. Make sure the old rubber stop is removed (it may become separated from the spring assembly). CAUTION: Use care not to damage any machined surfaces of the stator support. Remove and discard the (A) orifice cup plug and the (B) spring and stop assembly. Make sure the old (C) rubber stop is removed. Clean and inspect the bore, making sure it is clean of any debris. 6. Remove 12 bolts and separate the pump control body from the pump body. 7. CAUTION: Do not remove any of the remaining cup plugs unless directed to do so in other steps. Do not remove the stator support from the control body. This can distort the surface of the control body. NOTE: Inspect the main regulator booster valve and sleeve assembly. If the pump valve bore is not damaged but the valve and sleeve are worn replace the valve and sleeve. Remove the converter clutch shift valve assembly, converter regulator valve assembly, and main regulator boost valve and sleeve assembly. 1 Remove the retainer clip with a small screwdriver or tweezers then remove the converter clutch shift valve assembly. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > 4R100 > Page 5520 2 Remove the retainer clip with a small screwdriver or tweezers then remove the converter regulator valve assembly. 3 Remove the retainer clip with a small screwdriver or tweezers then remove the main regulator valve assembly. 8. Remove and inspect the (A) inner and the (B) outer gerotor gears. 1 Clean all pump parts in solvent. 2 Dry the parts with compressed air. 3 Inspect the pump gears, faces, gear teeth, pump housing and mating surfaces for damage or scoring. 4 Replace the entire pump if any part is damaged or worn. 9. Inspect the (A) converter hub bushing. If scored or excessively worn, replace the entire pump. Note the orientation of the (B) lube groove. 10. NOTE: The pump assemblies are model-dependent. Remove the coast clutch seals and discard. 1 Inspect the bushing for wear. If scored or worn, replace the entire pump. 2 Remove the coast clutch seals. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > 4R100 > Page 5521 11. Measure and record the depth of the inner, then the outer, pump gerotor gear face-to-pump body machined surface. 1 Place the pump gerotor gearset into the pump gear pocket and center it to the pump bushing diameter. 2 Using a depth micrometer, measure and record the depth of the inner gerotor gear face to the pump body machined surface. Repeat measurement for a total of three readings in equally spaced locations on the gear face. If the reading is not within specification, replace the front pump assembly. 3 Remove the (A) inner gear and reinstall the (B) outer gear. Repeat Substep 2 for the outer gerotor gear face. 12. Inspect the following: - All valve and plug bores for scoring or damage. - All passages for obstructions. - Mating surfaces for burrs and scoring. - All springs for distortion. - When dry, check all valves and plugs for free movement in their respective bores. Assembly 1. Install the main regulator valve and sleeve assembly, converter clutch shift valve assembly, and the converter regulator valve assembly. 1 Install the converter clutch control valve assembly. Then apply pressure to the end plug and install the retainer, making sure it is properly seated. 2 Install the converter regulator valve assembly. Then apply pressure to the end plug and install the retainer, making sure it is properly seated. 3 Install the main regulator boost valve and sleeve assembly. Then apply pressure to the main regulator booster sleeve and install the retainer, making sure it is properly seated. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > 4R100 > Page 5522 2. NOTE: Prior to installation, lightly lubricate the gerotor gears with clean Motorcraft MERCON Multi-Purpose (ATF) Transmission Fluid XT-2-QDX or equivalent Meeting MERCON specification. Install the (A) gerotor gearset, with the (B) dot facing the control body assembly. MERCON(R) automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4. 3. CAUTION: Prior to pump assembly, make sure all cup plugs are installed. CAUTION: Inspect mating surfaces of the pump body and the control body to make sure they are clean and free of nicks and burrs. Lower the (A) control body and stator assembly onto the (B) pump body, aligning the (C) 28 mm hole in each body. 4. NOTE: Make sure that the outer edges of the pump body and the outer bolt holes are aligned during assembly. Using the special tool, assemble the pump and loosely install 11 bolts. 1 Install the 10mm alignment bolt. 2 Tighten the bolts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > 4R100 > Page 5523 5. CAUTION: Make sure the (A) sea] grooves in the stator support are clean and free of burrs. CAUTION: Make sure the (B) seal ends are properly positioned together and not (C) separated. Install the 2 coast clutch Teflon seals. Make sure the seals are fully seated in the stator support seal grooves and the (D) seal ends are oriented 180 ° apart. 6. Install the pump outer diameter square-cut front pump seal. 7. Install the front pump stator support seal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > 4R100 > Page 5524 8. CAUTION: Failure to replace these parts may cause repeat repairs. NOTE: Install the rubber stop end into the bore first. Install the new spring and stop assembly. 9. NOTE: Make sure the edge of the cup plug is seated just below the stator support surface that mates with the No. 2 needle bearing assembly. Using a small drift and mallet, install the new orifice cup plug. 10. If removed, install the front pump sea], using the Front Pump Seal Replacer. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > 4R100 > Page 5525 11. NOTE: Lightly lubricate the thrust washer and the bearing with petroleum jelly to hold them in place during assembly. Install the No. 1 pump thrust washer and the No. 2A overdrive sun gear thrust bearing. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > 4R100 > Page 5526 Fluid Pump: Service and Repair 4R70W Special Tools Disassembly Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > 4R100 > Page 5527 1. Remove the No. 1 pump support thrust washer. 2. Remove the front pump support. 1 Remove the bolts. 2 Remove the front pump support. 3. NOTE: The reverse clutch cylinder seals are larger than the forward clutch cylinder rings. Remove the two (A) reverse clutch cylinder seals and the two (B) forward clutch cylinder seals. 4. Remove the (A) inner and (B) outer pump gerotor gears. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > 4R100 > Page 5528 5. Carefully pry spring retainer tabs and remove the spring retainer assembly. 6. Remove the intermediate clutch piston. 7. Replace the clutch piston seals. 1 Remove the intermediate clutch piston outer seal. 2 Remove the intermediate clutch piston inner seal. 8. Remove and discard the front pump seal. Assembly Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > 4R100 > Page 5529 1. Use (A) Front Pump Seal Replacer to install the (B) front pump seal assembly. 2. Install the clutch piston seals. 1 Install the intermediate clutch piston outer seal. 2 Install the intermediate clutch piston inner seal. 3. NOTE: Coat the intermediate clutch piston outer seal, intermediate clutch piston inner seal and pump body sealing area with petroleum jelly. Install the (A) intermediate clutch piston into (B) Clutch Lip Seal Protector. 4. Install the intermediate clutch piston. 1 Position the intermediate clutch piston and Clutch Lip Seal Protector onto the pump body. 2 Push the intermediate clutch piston to the bottom of the pump body bore, exerting even pressure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > 4R100 > Page 5530 5. CAUTION: The piston bleed hole must be located at 12 o'clock position towards the top of the transmission). Shift problems may occur if installed incorrectly. NOTE: The piston bleed hole is the only round hole in the pump body. Locate the piston bleed hole. 6. Install by snapping the spring retainer assembly on pump body. 7. NOTE: The flats on the inner fluid pump gear have steps that must face the pump body for ease of installing the torque converter. Install the (A) inner and (B) outer fluid pump gerotor gears. 8. NOTE: The reverse clutch cylinder seals are larger than the forward clutch cylinder seals. Install the (A) reverse clutch cylinder sea] and the (B) forward clutch cylinder seals. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair > 4R100 > Page 5531 9. Install new front pump seal. 10. Assemble the front pump. 1 Position the pump support to the pump body assembly. 2 Install the bolts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Tools and Equipment > 4R70W Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Tools and Equipment > 4R70W > Page 5534 Fluid Pump: Tools and Equipment 4R100 Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Shift Indicator > Component Information > Adjustments Shift Indicator: Adjustments 1. Remove the upper instrument panel steering column cover. 2. Place the gearshift lever in the (D) position. - Rotate the gearshift lever clockwise until it bottoms out (first gear), then rotate two detents counterclockwise (D) position). 3. Hang an eight pound weight on the gearshift lever. 4. Center the pointer in the middle of the (D) position. - Rotate the thumb wheel located on the bottom of the steering column to adjust the pointer. 5. Remove the eight pound weight. 6. Carefully move the gearshift lever from detent to detent and compare with transmission settings. Readjust if necessary. 7. Install the upper instrument panel steering column cover. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Specifications > 4R70W Output Shaft: Specifications Output Shaft Speed Sensor Bolt 8-16 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Specifications > 4R70W > Page 5543 Output Shaft: Specifications Output Shaft Speed Sensor Bolt 8-10 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Specifications > Page 5544 Output Shaft: Diagrams Part 1 Of 2 Part 2 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Specifications > Page 5545 Output Shaft: Testing and Inspection Special Tools Disassembly 1. CAUTION: Build-up of contamination can block the flow of lubricant behind the cup plug and cause transmission assembly damage. NOTE: The anti-seepage seal is intended for shipping purposes only. It is not necessary to remove and reuse this seal when replacing the output shaft. NOTE: The output shaft cannot be disassembled and must be replaced if damaged. Inspect the output shaft for wear. Make sure the cup plug orifice and lube passages through output shaft are clean and free of debris. Replace as required. 2. Inspect the bearing surfaces of the output shaft for wear or scores. If excessive wear or scores are found, replace output shaft and inspect mating components. 3. Check the splines on the output shaft for wear. Replace the output shaft if the splines are excessively worn. Inspect all the bushings for wear. Replace if worn or damaged. 4. Inspect the output shaft for damage. If damage is found, refer to the next two steps. 1 Inspect the output shaft. 2 Inspect the edges and the top of the output shaft drive sprocket speed sensor wheel. 3 Inspect the park gear. 5. NOTE: The park gear and output shaft drive sprocket speed sensor wheel will require removal or replacement if they are damaged. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Specifications > Page 5546 Using an arbor press remove the park gear. 6. NOTE: If replacing the output shaft drive sprocket speed sensor wheel, the park gear will need to be removed first. If required, use an arbor press and the remover/replacer tube to remove the park gear. Remove the park gear. Assembly 1. NOTE: If any damage is found to the output shaft drive sprocket speed sensor wheel it will need to be replaced. If removed, use the arbor press and the remover replacer tube to install the park gear, press the park gear onto the output shaft until it stops at the shoulder on the output shaft. 2. If removed, install the output shaft drive sprocket speed sensor wheel using the installation tool. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Specifications > Page 5547 Output Shaft: Service and Repair Special Tools Part 1 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Specifications > Page 5548 Part 2 Of 2 Disassembly 1. NOTE: The yellow dot on the output shaft must be aligned with the yellow dot on the output shaft ring gear during the assembly procedure. Remove the ring gear snap ring. 2. Separate the (A) ring gear and (B) output shaft. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Specifications > Page 5549 3. Remove the three output shaft seal rings. 4. Remove the (A) output shaft hub snap ring and the (B) output shaft hub. 5. Remove the two direct clutch seal rings. 6. Remove the (A) direct clutch hub and the (B) bearing and direct clutch inner bearing support. 7. Inspect the clutch cylinder thrust surfaces, piston bore and clutch plate serrations for scores or burrs. Minor scores or burrs may be removed with a crocus cloth. Replace the clutch cylinder if badly scored or damaged. 8. Check the fluid passage in the clutch cylinder for obstructions. Clean out all fluid passages. Inspect the clutch piston for scores and replace if necessary. Inspect the check balls for freedom of movement and proper seating. 9. Check clutch release spring for distortion and cracks. Replace spring (including wave spring) if distorted or cracked. 10. Inspect composition clutch plates, steel clutch plates and clutch pressure plate for worn or scored bearing surfaces. Replace all parts that are deeply scored or burred. 11. Check the clutch plates for flatness and fit on the clutch hub serrations. Discard any plate that does not slide freely on the serrations or that is not flat. 12. Check the clutch hub thrust surfaces for scores and clutch hub splines for wear. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Specifications > Page 5550 13. Remove the direct clutch pack. 1 Remove the retaining ring. 2 Remove the direct clutch pack. 14. Use (A) Clutch Spring Compressor to compress the piston return spring and remove the (B) snap ring. 15. WARNING: Wear safety glasses when using compressed air. NOTE: If necessary, use regulated compressed air (207 kPa [30 psi] max pressure) to remove the clutch piston. Remove the support and spring assembly and piston. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Specifications > Page 5551 16. Remove the inner piston seal. 17. Remove the outer piston seal. Assembly 1. NOTE: Lubricate direct clutch piston inner seal and seal protector with petroleum jelly. Position (A) Direct Clutch Lip Seal Protector over the clutch cylinder hub and install the (B) inner piston seal. Install the seal with sealing lip facing down. 2. Install the clutch piston outer seal so that when the piston is installed the sealing lip points toward the bottom of the cylinder. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Specifications > Page 5552 3. NOTE: Coat the inner and outer direct clutch piston seals, clutch cylinder sealing area and piston inner sealing area with petroleum jelly. Use (A) Direct Clutch Lip Seal Protector to install the (B) direct clutch piston. 4. Install the piston return spring and retainer assembly. 5. Use (A) Clutch Spring Compressor to compress the piston return spring and install the (B) retaining ring. 6. NOTE: Before assembly, soak new clutch discs in transmission fluid for 15 minutes. Install the clutch pack retaining ring. 1 Alternate external spline (steel) plates and internal spline (friction) plates, starting with a steel plate and ending with the friction plate. 2 Install the clutch pack retaining ring. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Specifications > Page 5553 7. Use a (A) feeler gauge to check the clearance between the (B) clutch pack retaining ring and the (C) pressure plate. - If the clearance is not within specifications, install the correct size retaining ring and recheck the clearance. 8. Install the washer and the (B) No. 7 needle bearing on the (A) direct clutch hub and install the direct clutch hub. - Install the needle bearing with the black side up, toward the direct clutch hub. NOTE: Inspect the output shaft bearing surfaces for scores. Inspect the output shaft splines for wear. Inspect all bushings. 9. CAUTION: Make sure the seals are lapped correctly. Internal damage may occur. Install the two direct clutch seal rings. 10. Install the output shaft hub. - Position the output shaft hub. - Install the retaining ring. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Specifications > Page 5554 11. Install the three output shaft seal rings. 12. Install the No. 8 needle bearing on the direct clutch cylinder. 13. NOTE: Direct clutch cylinder may be installed after the output shaft ring gear is installed to the output shaft hub. Assemble the direct clutch on the output shaft. 14. NOTE: The yellow dot on the output shaft must be aligned with the yellow dot on the output shaft ring gear. Align the yellow dots on output shaft and the output shaft ring gear and install the ring gear on the output shaft. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Tools and Equipment > 4R70W Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Tools and Equipment > 4R70W > Page 5557 Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Description and Operation Overdrive Switch: Description and Operation The Transmission Control Switch (TCS) is a momentary contact switch that is located on the end of the transmission control selector lever. Pushing the TCS will either disengage or engage the overdrive function of the transmission. if the OVERDRIVE is disengaged, the word OFF will illuminate on the transmission control selector lever. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Switch, A/T > Component Information > Description and Operation > Page 5561 Overdrive Switch: Service and Repair Removal 1. Remove the Transmission Control Switch (TCS). 1 Remove the TCS cover. 2 Remove the TCS. Installation 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Park Gear, A/T > Component Information > Service and Repair Park Gear: Service and Repair Removal NOTE: For internal park mechanism service, refer to Manual Control Lever Shaft and Seal. 1. Remove the extension housing and the extension housing gasket. 2. Remove the parking rod guide plate. 1 Remove the bolts. 2 Remove the parking rod guide plate. 3. NOTE: If the park gear replacement is required; refer to Output Shaft-Check. Remove the park pawl shaft. 1 Remove the park pawl return spring. 2 Remove the park pawl. 3 Remove the park pawl shaft. Installation 1. NOTE: If the park gear replacement is required; refer to Output Shaft/Testing and Inspection. Install the park pawl shaft. 1 Install the park pawl shaft. 2 Install the park pawl. 3 Install the park pawl return spring. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Park Gear, A/T > Component Information > Service and Repair > Page 5565 2. Install the parking rod guide plate. 1 Install the parking rod guide plate. 2 Install the bolts. 3. Install the extension housing gasket and the extension housing. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Specifications Parking Pawl: Specifications Parking Pawl Abutment ....................................................................................................................... .................................................................. 22-27 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > Customer Interest for Planetary Gears: > 01-13-7 > Jul > 01 > A/T 4R70W Clunk Noise on 2nd to 1st Gear Downshift Planetary Gears: Customer Interest A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift Article No. 01-13-7 07/09/01 ^ NOISE - "CLUNK" NOISE HEARD ON 2-1 DOWNSHIFT VEHICLES EQUIPPED WITH 4R70W AUTOMATIC TRANSMISSION ^ TRANSMISSION - 4R70W - "CLUNK" NOISE HEARD FROM TRANSMISSION ON 2-1 DOWNSHIFT FORD: 1999-2001 CROWN VICTORIA, MUSTANG 1999 F-250 LD 1999-2001 E SERIES, EXPEDITION, EXPLORER, F-150 LINCOLN: 1999-2001 TOWN CAR MERCURY: 1999-2001 GRAND MARQUIS, MOUNTAINEER ISSUE Some vehicles equipped with a 4R70W automatic transmission may exhibit a "clunk" noise during the 2-1 downshift event. The "clunk" noise will be consistent in nature, and will occur during most 2-1 downshifts. This may be caused by a Planet Support Spring that is out of position. ACTION Check for the correct installation of the Planet Support Spring. If the spring is not installed correctly, the Planetary Gear Support will make contact with the transmission case during the 2-1 downshift, causing the "clunk" noise. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE THE "CLUNK" NOISE DESCRIBED IN THIS ARTICLE SHOULD NOT BE CONFUSED WITH HARSH/ROUGH 2-1 DOWNSHIFT CONDITION. IF A HARSH/ROUGH 2-1 SHIFT CONDITION IS PRESENT, FOLLOW NORMAL WORKSHOP MANUAL DIAGNOSTIC PROCEDURES. 1. Use Chassis Ears (Rotunda number 107-R2102 or equivalent) to verify the "clunk" noise is originating from the transmission during the 2-1 downshift event. NOTE IF THE NOISE IS NOT ORIGINATING FROM THE TRANSMISSION DO NOT CONTINUE WITH THIS SERVICE PROCEDURE. USE THE CHASSIS EARS TO HELP PINPOINT THE ORIGIN OF THE NOISE, THEN DIAGNOSE AND REPAIR AS NEEDED. 2. Raise and support vehicle. Refer to Workshop Manual Section 100-02. 3. Check for correct torque on the following chassis & drivetrain components: ^ Driveshaft to Pinion Flange fasteners ^ Upper and Lower Control Arm fasteners (car applications) ^ Rear Leaf Spring Fasteners (truck applications) ^ Rear Shock Absorber fasteners ^ Transmission Mount and Crossmember fasteners 4. If any discrepancies are found, correct and test drive vehicle to verify repair. If condition is not corrected, continue to Step 5. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > Customer Interest for Planetary Gears: > 01-13-7 > Jul > 01 > A/T 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 5577 5. Remove the transmission from the vehicle and disassemble down to and including the Center Support Retaining Ring. Refer to Workshop Manual section 307-01. 6. Note the position of the Planet Support Spring. Compare to the correct installation which is illustrated in Figure 1. One tang of the Planet Support Spring should be loaded against the transmission case. The other tang should be loaded against the Planetary Gear Support. 7. Unless the Planet Support Spring is damaged, it may be reinstalled in the transmission correctly. If the spring is damaged, replace with part number F5AZ-7F277-AA. 8. Install the Planet Support Spring in the position illustrated in Figure 1. Use a flat/wide tool, that will apply equal force across the spring. This will ensure the spring is installed squarely with the tangs loading the Transmission Case on one side and the Planetary Gear Support on the other. 9. Reassemble and install the transmission. Replace the Pump Gasket during reassembly. Part number F2VY-7A136-A. 10. Lower vehicle, refill fluid to correct level and verity repair. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > Customer Interest for Planetary Gears: > 01-13-7 > Jul > 01 > A/T 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 5578 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > Customer Interest for Planetary Gears: > 01-13-7 > Jul > 01 > A/T 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 5579 Operation/Description/Time DEALER CODING CONDITION BASIC PART NO. CODE 7F277 07 OASIS CODES: 502000, 504000, 597997 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Planetary Gears: > 01-13-7 > Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift Planetary Gears: All Technical Service Bulletins A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift Article No. 01-13-7 07/09/01 ^ NOISE - "CLUNK" NOISE HEARD ON 2-1 DOWNSHIFT VEHICLES EQUIPPED WITH 4R70W AUTOMATIC TRANSMISSION ^ TRANSMISSION - 4R70W - "CLUNK" NOISE HEARD FROM TRANSMISSION ON 2-1 DOWNSHIFT FORD: 1999-2001 CROWN VICTORIA, MUSTANG 1999 F-250 LD 1999-2001 E SERIES, EXPEDITION, EXPLORER, F-150 LINCOLN: 1999-2001 TOWN CAR MERCURY: 1999-2001 GRAND MARQUIS, MOUNTAINEER ISSUE Some vehicles equipped with a 4R70W automatic transmission may exhibit a "clunk" noise during the 2-1 downshift event. The "clunk" noise will be consistent in nature, and will occur during most 2-1 downshifts. This may be caused by a Planet Support Spring that is out of position. ACTION Check for the correct installation of the Planet Support Spring. If the spring is not installed correctly, the Planetary Gear Support will make contact with the transmission case during the 2-1 downshift, causing the "clunk" noise. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE THE "CLUNK" NOISE DESCRIBED IN THIS ARTICLE SHOULD NOT BE CONFUSED WITH HARSH/ROUGH 2-1 DOWNSHIFT CONDITION. IF A HARSH/ROUGH 2-1 SHIFT CONDITION IS PRESENT, FOLLOW NORMAL WORKSHOP MANUAL DIAGNOSTIC PROCEDURES. 1. Use Chassis Ears (Rotunda number 107-R2102 or equivalent) to verify the "clunk" noise is originating from the transmission during the 2-1 downshift event. NOTE IF THE NOISE IS NOT ORIGINATING FROM THE TRANSMISSION DO NOT CONTINUE WITH THIS SERVICE PROCEDURE. USE THE CHASSIS EARS TO HELP PINPOINT THE ORIGIN OF THE NOISE, THEN DIAGNOSE AND REPAIR AS NEEDED. 2. Raise and support vehicle. Refer to Workshop Manual Section 100-02. 3. Check for correct torque on the following chassis & drivetrain components: ^ Driveshaft to Pinion Flange fasteners ^ Upper and Lower Control Arm fasteners (car applications) ^ Rear Leaf Spring Fasteners (truck applications) ^ Rear Shock Absorber fasteners ^ Transmission Mount and Crossmember fasteners 4. If any discrepancies are found, correct and test drive vehicle to verify repair. If condition is not corrected, continue to Step 5. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Planetary Gears: > 01-13-7 > Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 5585 5. Remove the transmission from the vehicle and disassemble down to and including the Center Support Retaining Ring. Refer to Workshop Manual section 307-01. 6. Note the position of the Planet Support Spring. Compare to the correct installation which is illustrated in Figure 1. One tang of the Planet Support Spring should be loaded against the transmission case. The other tang should be loaded against the Planetary Gear Support. 7. Unless the Planet Support Spring is damaged, it may be reinstalled in the transmission correctly. If the spring is damaged, replace with part number F5AZ-7F277-AA. 8. Install the Planet Support Spring in the position illustrated in Figure 1. Use a flat/wide tool, that will apply equal force across the spring. This will ensure the spring is installed squarely with the tangs loading the Transmission Case on one side and the Planetary Gear Support on the other. 9. Reassemble and install the transmission. Replace the Pump Gasket during reassembly. Part number F2VY-7A136-A. 10. Lower vehicle, refill fluid to correct level and verity repair. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Planetary Gears: > 01-13-7 > Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 5586 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Planetary Gears: > 01-13-7 > Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 5587 Operation/Description/Time DEALER CODING CONDITION BASIC PART NO. CODE 7F277 07 OASIS CODES: 502000, 504000, 597997 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Technical Service Bulletins > Page 5588 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair Pressure Regulating Solenoid: Service and Repair Electronic Pressure Control (EPC) Solenoid Removal 1. Remove the manual control lever. 2. CAUTION: Do not pull on the plastic lead frame. This may cause damage to the connector ends. Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame from the solenoids. Disconnect the molded lead frame from the solenoids. 1 Disconnect the shift solenoid SSA and SSB. 2 Disconnect the Torque Converter Clutch (TCC). 3 Disconnect the Electronic Pressure Control (EPC) solenoid. 4 Disconnect the bulkhead inter-connector. 3. Remove the EPC solenoid. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Page 5592 1. Install the EPC solenoid. 2. Connect the molded lead frame to the solenoids. - Connect the bulkhead inter-connector. - Connect the Electronic Pressure Control (EPC) solenoid. - Connect the Torque Converter Clutch (TCC). - Connect the shift solenoid SSA and SSB. 3. Install the manual control lever. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair Seals and Gaskets: Service and Repair Special Tools Special Tools Removal 1. Disconnect the battery ground cable. 2. NOTE: 4x2 shown, 4x4 similar. Raise the vehicle on a hoist. 3. Remove the driveshaft. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Page 5596 4. With a suitable drain pan properly positioned, remove the (A) extension housing seal, using the (B) Seal Remover and the (C) Impact Slide Hammer. 5. CAUTION: Do not damage any machined surfaces. Damage may cause the new seal to leak. Using the (A) Extension Housing Bushing Remover, remove the (B) extension housing bushing. Installation 1. CAUTION: Prior to installing the extension housing bushing, inspect the extension housing counterbore for burrs. If necessary, remove the burrs with an oil stone or damage to new bushing may occur. NOTE: The extension housing bushing is model dependent. Align the extension housing bushing in the extension housing so that the slots are in the 2 o'clock and 7 o'clock positions. 2. Using the (A) Extension Housing Bushing Replacer, install the (B) extension housing bushing. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Page 5597 3. Align the (A) extension housing seal in the extension housing, with the (B) drain hole positioned downward. 4. Using the (A) Extension Housing Seal Replacer, seat the extension housing seal into the (B) extension housing. 5. Install the driveshaft. 6. Lower the vehicle. 7. Reconnect the battery ground cable. 8. Fill the transmission to the specified level with Motorcraft Motorcraft MERCON Multi-Purpose (ATF) Transmission Fluid XT-2-QDX or equivalent Meeting MERCON specification. MERCON(R) automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Page 5598 Seals and Gaskets: Tools and Equipment Special Tools Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Description and Operation Overdrive Switch: Description and Operation The Transmission Control Switch (TCS) is a momentary contact switch that is located on the end of the transmission control selector lever. Pushing the TCS will either disengage or engage the overdrive function of the transmission. if the OVERDRIVE is disengaged, the word OFF will illuminate on the transmission control selector lever. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Description and Operation > Page 5603 Overdrive Switch: Service and Repair Removal 1. Remove the Transmission Control Switch (TCS). 1 Remove the TCS cover. 2 Remove the TCS. Installation 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > 4R70W Transmission Position Switch/Sensor: Specifications Digital Transmission Range Sensor Bolts 7-10 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > 4R70W > Page 5608 Transmission Position Switch/Sensor: Specifications Digital Transmission TR Sensor 8-10 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5609 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W Transmission Position Switch/Sensor: Service and Repair 4R70W Special Tools 1. Raise and support vehicle. 2. Disconnect the manual lever shift control cable. 3. Disconnect the digital TR electrical connector. 4. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. The old nut will not retain torque specification. Remove the manual control lever. 1 Remove the nut. 2 Remove the lever. 5. Loosen the digital TR sensor bolts. 6. NOTE: Manual shift lever must be in the neutral position. Use digital transmission range TR Sensor Alignment Tool, to align the digital TR sensor slots. The tool is designed to fit snug. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W > Page 5612 7. Tighten the bolts. 8. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual lever shaft outer nut. 9. With the manual lever in overdrive connect the shift lever control cable. 10. Install the digital TR sensor electrical connector. 11. Lower the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W > Page 5613 Transmission Position Switch/Sensor: Service and Repair 4R100 Special Tools Removal 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Disconnect the connector. 4. Disconnect the shift cable at the manual control lever. 5. Remove the digital Transmission Range (TR) sensor. 1 Remove the bolts. 2 Remove the digital Transmission Range (TR) sensor. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W > Page 5614 1. Install the digital Transmission Range (TR) sensor. 1 Install digital Transmission Range (TR) sensor. 2 Loosely install the bolts. 2. NOTE: Make sure that the manual control lever is in the neutral position. Install the Digital Transmission Range (TR) Sensor Alignment Tool. The tool is designed to fit snug. 3. Tighten the bolts. 4. Reconnect the shift cable at the manual control lever. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W > Page 5615 5. Reconnect the connector. 6. Lower the vehicle. 7. Reconnect the battery ground cable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Tools and Equipment > 4R70W Special Tool Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Tools and Equipment > 4R70W > Page 5618 Special Tool Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed Sensor Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed Sensor > Page 5623 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5624 Transmission Speed Sensor: Service and Repair Removal 1. Remove the drive shaft. 2. Remove the rear transmission mount nuts. 3. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the TSS and OSS sensors will occur. Remove the rear transmission mount. 1 Raise the transmission up off the rear crossmember support. 2 Remove the bolts. 3 Remove the rear transmission mount. 4. Lower the transmission to gain access to the Turbine Shaft Speed (TSS) sensor, and the Output Shaft Speed (OSS) sensor. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5625 5. Remove the Turbine Shaft Sensor (TSS). 1 Remove the bolt. 2 Remove the Turbine Shaft Sensor (TSS). 6. Remove the Output Shaft Speed (OSS) sensor. 1 Remove the bolt. 2 Remove the Output Shaft Speed (OSS) sensor. Installation 1. Install the Output Shaft Speed (OSS) sensor. 1 Lubricate the O-ring and install the Output Shaft Speed (OSS) sensor. 2 Install the bolt. 2. Install the Turbine Shaft Sensor (TSS). 1 Lubricate the O-ring and install the Turbine Shaft Sensor (TSS). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5626 2 Install the bolt. 3. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the sensors will occur. Install the rear transmission mount. 1 Raise the transmission up. 2 Install the rear transmission mount. 3 Install the bolts. 4. Lower the transmission on to the rear crossmember support. 5. Install the rear transmission mount nuts. 6. Install the drive shaft. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Specifications Shift Interlock Solenoid: Specifications Shift Lock Actuator Bolts 7-11 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 5631 Shift Interlock Solenoid: Service and Repair Removal 1. Remove the steering column assembly. 2. Remove the insert plate and shift lock actuator. 1 Remove the bolts. 2 Remove the insert plate and shift lock actuator. 3. NOTE: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to be replaced in the field. Remove the insert plate from the shift lock actuator. Remove and discard the shift lock actuator clip. Installation 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair Shift Solenoid: Service and Repair Refer to Valve Body for service procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Specifications Shifter A/T: Specifications TORQUE SPECIFICATIONS Selector Lever Arm And Support Bolts ..................................................................................................................................... 13-17 Nm (10-13 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Specifications > Page 5638 Shifter A/T: Service and Repair Removal 1. Remove the ignition switch lock cylinder. 2. Remove the upper steering column shroud. 3. Remove the gearshift lever. 1 Disconnect the electrical connector. 2 Remove and discard the gearshift lever pin. 3 Remove the gearshift lever. Installation 1. NOTE: The gearshift lever pin must be replaced whenever removed. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Specifications Selector Shaft: Specifications Manual Lever Shaft Inner Nut 26-37 Nm Manual Lever Shaft Outer Nut 30-35 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Service and Repair > 4R70W Selector Shaft: Service and Repair 4R70W Removal 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. NOTE: Mark the driveshaft flange and rear axle companion flange for correct alignment during installation. On 4x4 vehicles, remove the front driveshaft. 1 Remove the eight front driveshaft bolts (four each end). 2 Remove the front driveshaft. 4. Drain the transmission fluid and remove the fluid pan and filter. 5. Disconnect digital TR sensor electrical connector. 6. Disconnect the transmission shift linkage. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Service and Repair > 4R70W > Page 5645 7. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. The old nut will not retain torque specification. Remove the manual control lever. 1 Remove the outer manual control lever shaft nut. 2 Remove the manual control lever. 8. Remove the transmission range digital TR sensor. 1 Remove the two bolts. 2 Remove the digital TR sensor. 9. Remove the manual control valve detent lever spring. 1 Remove the bolt. 2 Remove the manual control valve detent lever spring. 10. NOTE: Use a shop cloth to protect the transmission case surface. Remove the manual lever shaft retaining pin. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Service and Repair > 4R70W > Page 5646 11. Remove the inner manual control lever shaft nut and slide the manual control lever shaft out of the case. 12. Remove the parking lever actuating rod. 1 Remove the manual valve detent lever. 2 Remove the parking lever actuating rod. 13. CAUTION: Use care not to damage the manual control lever shaft bore. New seal may leak. Remove the manual control lever shaft seal. Installation 1. Use (A) Shift Lever Seal Replacer to install the (B) manual control lever seal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Service and Repair > 4R70W > Page 5647 2. Install the parking lever actuating rod. 1 Install the parking lever actuating rod. 2 Install the manual valve detent lever. 3. Install the manual control lever shaft. 1 Install the manual control lever shaft. 2 Install the nut. 3 Install the pin. 4. Install the manual valve detent lever spring. 1 Position the manual valve detent lever spring. 2 Install the bolt. 5. Install the digital TR sensor. 1 Install the digital TR sensor. 2 Loosely install the bolts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Service and Repair > 4R70W > Page 5648 6. NOTE: The manual shift lever must be in the neutral position. Use the Digital Transmission Range (TR) Sensor Alignment Tool to align the digital TR sensor slots. The tool is designed to fit snug. 7. Tighten the bolts. 8. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual lever shaft outer nut. 9. With manual lever in OVERDRIVE, connect the shift control cable. 10. Install digital TR sensor electrical connector. 11. Install the filter and transmission fluid pan. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Service and Repair > 4R70W > Page 5649 12. On 4x4 vehicles, install the front driveshaft. 1 Position the front driveshaft. 2 Install the eight bolts (four each end). 13. Lower the vehicle. 14. Connect the battery ground cable. 15. Fill the transmission with fluid and inspect for proper operation. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Service and Repair > 4R70W > Page 5650 Selector Shaft: Service and Repair 4R100 Removal 1. Remove the fluid pan gasket and filter. 2. Disconnect the shift cable. 1 Disconnect the shift cable from the manual lever. 2 Disconnect the cable housing from the bracket; position aside. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Service and Repair > 4R70W > Page 5651 3. Disconnect the digital Transmission Range (TR) sensor electrical connector. 4. Remove the Digital Transmission (TR) sensor. 1 Remove the bolts. 2 Remove the digital Transmission Range (TR) sensor. 5. NOTE: A No. 53 drill bit (1/16 inch) can be used instead to remove the manual lever shaft retaining pin. Remove the manual lever shaft retaining pin. 1 Insert the Lock Nut Pin Remover into the retaining pin. 2 Remove the manual lever shaft retaining pin. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Service and Repair > 4R70W > Page 5652 6. CAUTION: Be careful not to damage the manual control lever bore. NOTE: The manual control lever and manual control lever shaft are one piece. NOTE: Use a crescent wrench on the manual control lever or outer flats of manual control lever shaft assembly when removing the inner manual valve detent lever nut. Remove the manual control lever shaft assembly. 1 Remove the nut. 2 Remove the manual control lever shaft assembly. 7. Remove the manual control lever seal. 1 Install the Puller. 2 Remove the seal. Installation 1. NOTE: Prior to installing the manual control lever seal, clean the bore opening with mineral spirits. Using the Shift Lever Seal Replacer to install the manual control lever seal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Service and Repair > 4R70W > Page 5653 2. Install the manual control lever shaft assembly. 1 Install the manual control lever shaft assembly. 2 Install and seat the manual lever shaft retaining pin below the case surface. 3 NOTE: The inner manual valve detent lever must be seated on the flats of the manual control lever shaft assembly, and the parking pawl actuating rod must be through the guide plate. NOTE: The manual control valve detent lever spring must be on the inner manual valve detent lever, and the detent lever pin must align with the manual shift valve. Install the (A) parking pawl actuating rod and the (B) inner manual valve detent lever. 4 NOTE: Use a crescent wrench on the manual control lever or the outer flats of the manual control lever shaft assembly when installing the inner manual valve detent lever nut. Install the inner manual valve detent lever nut. 3. Install the digital Transmission Range (TR) sensor. 1 Position the digital transmission range sensor. 2 Loosely install the bolts. 4. NOTE: Make sure that the manual control lever is in the neutral position. Install the Digital Transmission Range (TR) Sensor Alignment Tool. The tool is designed to fit snug. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Service and Repair > 4R70W > Page 5654 5. Tighten the bolts. 6. Connect the digital Transmission Range (TR) sensor electrical connector. 7. Connect the shift cable. 1 Install the cable housing to the bracket. 2 Install the shift cable to the manual lever. 8. Install filter and seal assembly, fluid pan and gasket. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Tools and Equipment > 4R70W Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Selector Shaft, A/T > Component Information > Tools and Equipment > 4R70W > Page 5657 Selector Shaft: Tools and Equipment 4R100 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > 4R70W Shift Cable: Specifications Cable Bracket Bolts 30-40 Nm Shift Cable Bracket Nut 17-23 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Specifications > 4R70W > Page 5662 Shift Cable: Specifications Shift Cable Bracket Bolts 30-40 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > 4R70W Shift Cable: Adjustments 4R70W 1. Place the gearshift lever in the (D) position. - Place a three pound weight on the gearshift lever. 2. Raise and support the vehicle. 3. Disconnect the transmission shift cable from the manual control lever. 4. Unlock the lock tab on the transmission shift cable. 5. Place the manual control lever in the (D) position. 1 Place the manual control lever in the first gear position. 2 Move the manual control lever two detents to the (D) position. 6. Connect the transmission shift cable to the manual control lever. 7. Lock the transmission shift cable lock tab. 8. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. 9. Remove the three pound weight. 10. Carefully move the gearshift lever from detent to detent and compare with transmission settings. Verify that the vehicle will start in PARK or NEUTRAL and backup lamps illuminate in REVERSE. If not, Steps 1-5 must be repeated and include digital TR sensor adjustment in NEUTRAL. Readjust if necessary. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > 4R70W > Page 5665 Shift Cable: Adjustments 4R100 1. Place the gearshift lever in the (D) position. - Place a three pound weight on the gearshift lever. 2. Raise and support the vehicle. 3. Disconnect the transmission shift cable from the manual lever. 4. Unlock the lock tab on the transmission shift cable. 5. Place the manual control lever in the (D) position. 1 Place the manual control lever in the first gear position. 2 Move the manual control lever two detents to the (D) position. 6. Connect the transmission shift cable to the manual control lever. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > 4R70W > Page 5666 7. Lock the transmission shift cable lock tab. 8. Lower the vehicle. 9. Remove the eight pound weight. 10. Carefully move the gearshift lever from detent to detent and compare with transmission settings. Verify that the vehicle will start in PARK or NEUTRAL and backup lamps illuminate in REVERSE. If not, Steps 1-5 must be repeated and include digital TR or TR sensor adjustment in NEUTRAL. Readjust if necessary. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 5667 Shift Cable: Service and Repair Removal 1. Disconnect the transmission shift cable from the steering column. 1 Disconnect the transmission shift cable from the steering column shift tube lever. 2 Remove the cable push pin. 3 Unlock and remove the transmission shift cable from the steering column bracket. 2. Push the rubber grommet and transmission shift cable through the bulkhead. 3. Raise and support the vehicle. 4. Remove the transmission shift cable from the transmission. 1 Disconnect the transmission shift cable from the manual control lever. 2 Depress the lock tabs to release the transmission shift cable and disconnect the transmission shift cable from the transmission shift cable bracket. 5. 4.6L with 4R70W Transmission-Remove the shift cable bracket from the transmission. 1 Remove the bolts. 2 Remove the bracket. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 5668 6. 5.4L with 4R100 Transmission-Remove the shift cable bracket from the transmission. 1 Remove the bolts. 2 Remove the shift cable bracket. Installation 1. Follow the removal procedure in reverse order. - Prior to installing the shift cable, verify the digital TR sensor adjustment. - Adjust the shift cable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > A/T - 4R70W Needle Bearing/Race Kit Service Tip Sun Gear: Technical Service Bulletins A/T - 4R70W Needle Bearing/Race Kit Service Tip Article No. 03-26-1 01/12/04 TRANSMISSION - 4R70W - NEW SERVICE PART - NUMBER 5 NEEDLE BEARING AND RACE KIT - SERVICE TIP FORD: 1994-1997 THUNDERBIRD, 1994-2003 CROWN VICTORIA, MUSTANG, E SERIES 1996-2001 EXPLORER 1994-2003 F SERIES LINCOLN: 1994-1998 MARK VIII 1994-2003 TOWN CAR MERCURY: 1994-1997 COUGAR 1994-2003 GRAND MARQUIS 1997-2001 MOUNTAINEER ISSUE Should repairs become necessary on a 4R70W transmission involving replacement of the forward or reverse clutch sungear, and/or the number five (# 5) thrust bearing, these service pants all must be replaced in combination. A mismatch of service parts may cause an internal noise or a loss of forward and/or reverse. A new service kit has been produced to eliminate the mismatch of service pants. This new kit services all 4R70W transmissions built prior to the 2004 model. ACTION A new Service Kit 4L3Z-7D234-M has been produced to eliminate the mismatch of service parts. The kit contains the following: ^ A new two (2) piece number five (# 5) thrust bearing assembly (70234 bearing and 70235 race) (Figure 1) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > A/T - 4R70W Needle Bearing/Race Kit Service Tip > Page 5673 ^ A forward clutch sun gear (7A399) (Figure 2) ^ A reverse sun gear (7A019) (Figure 3) SERVICE TIP To install, refer to the latest version Workshop Manual for disassembly and reassembly of the transmission. CAUTION ALL COMPONENTS IN THE KIT MUST BE INSTALLED OR THE REPAIR MAY NOT BE EFFECTIVE AND MAY CAUSE AN INTERNAL NOISE OR LOSS OF FORWARD AND~OR REVERSE. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > A/T - 4R70W Needle Bearing/Race Kit Service Tip > Page 5674 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > Page 5675 Sun Gear: Diagrams Part 1 Of 2 Part 2 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Service and Repair > 4R70W Sun Gear: Service and Repair 4R70W Part 1 Of 2 Reverse Sun Gear, Disassembled View (Part 2 Of 2) Disassembly 1. Remove the (A) reverse sun gear assembly and the (B) No. 4 forward clutch hub bearing. 2. Remove the (A) forward clutch sun gear and the (B) No. 5 forward clutch sun gear bearing. Assembly Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Service and Repair > 4R70W > Page 5678 1. The forward clutch sun gear and reverse sun gear assembly are assembled as part of the transmission assembly procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Service and Repair > 4R70W > Page 5679 Sun Gear: Service and Repair 4R100 Disassembly 1. Remove and discard the forward/reverse sun gear retaining ring. 2. Remove the No. 14 input shell thrust washer. 3. Remove the forward/reverse sun gear. Assembly 1. Follow the removal procedure in reverse order. - Install the sun gear with the lube hole between the stand-off pads on the input shell. - Use care not to overextend the new retaining ring. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Thrust Washer/Bearing, A/T > Component Information > Technical Service Bulletins > A/T - 4R70W Needle Bearing/Race Kit Service Tip Thrust Washer/Bearing: Technical Service Bulletins A/T - 4R70W Needle Bearing/Race Kit Service Tip Article No. 03-26-1 01/12/04 TRANSMISSION - 4R70W - NEW SERVICE PART - NUMBER 5 NEEDLE BEARING AND RACE KIT - SERVICE TIP FORD: 1994-1997 THUNDERBIRD, 1994-2003 CROWN VICTORIA, MUSTANG, E SERIES 1996-2001 EXPLORER 1994-2003 F SERIES LINCOLN: 1994-1998 MARK VIII 1994-2003 TOWN CAR MERCURY: 1994-1997 COUGAR 1994-2003 GRAND MARQUIS 1997-2001 MOUNTAINEER ISSUE Should repairs become necessary on a 4R70W transmission involving replacement of the forward or reverse clutch sungear, and/or the number five (# 5) thrust bearing, these service pants all must be replaced in combination. A mismatch of service parts may cause an internal noise or a loss of forward and/or reverse. A new service kit has been produced to eliminate the mismatch of service pants. This new kit services all 4R70W transmissions built prior to the 2004 model. ACTION A new Service Kit 4L3Z-7D234-M has been produced to eliminate the mismatch of service parts. The kit contains the following: ^ A new two (2) piece number five (# 5) thrust bearing assembly (70234 bearing and 70235 race) (Figure 1) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Thrust Washer/Bearing, A/T > Component Information > Technical Service Bulletins > A/T - 4R70W Needle Bearing/Race Kit Service Tip > Page 5684 ^ A forward clutch sun gear (7A399) (Figure 2) ^ A reverse sun gear (7A019) (Figure 3) SERVICE TIP To install, refer to the latest version Workshop Manual for disassembly and reassembly of the transmission. CAUTION ALL COMPONENTS IN THE KIT MUST BE INSTALLED OR THE REPAIR MAY NOT BE EFFECTIVE AND MAY CAUSE AN INTERNAL NOISE OR LOSS OF FORWARD AND~OR REVERSE. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Thrust Washer/Bearing, A/T > Component Information > Technical Service Bulletins > A/T - 4R70W Needle Bearing/Race Kit Service Tip > Page 5685 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Customer Interest: > 02-21-1 > Oct > 02 > A/T - Torque Converter Access Plug Dislodges Torque Converter: Customer Interest A/T - Torque Converter Access Plug Dislodges Article No. 02-21-1 10/28/02 TRANSMISSION - 4R100/E4OD - TORQUE CONVERTER ACCESS EXTERNAL DUST PLUG MAY BECOME DISLODGED FORD: 1989-1996 BRONCO 1989-1997 F SUPER DUTY 1989-1998 F-250 LD, F-53 MOTORHOME 1989-2003 E SERIES, F-150 1997-2003 EXPEDITION 1999-2003 SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2000-2003 EXCURSION LINCOLN: 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD ISSUE Some vehicles equipped with the E4OD/4R100 transmission may exhibit the torque converter external access dust plug dislodging and falling out during severe duty use. This may be caused by a combination of stack up tolerance, material shrinkage over time and loading being applied to the plug during usage or cleaning of the underside of the vehicle. ACTION Obtain new plug (E9TZ-7N171-A) and apply 1/4" bead of silicone sealant around entire perimeter of part and install plug into transmission case. The silicone is to be applied in the groove of the part such that when it is installed, the sealant will till any gaps between the transmission case and the plug. SERVICE PROCEDURE 1. Obtain service part E9TZ-7N171-A, F7TZ-19554-AA and general purpose degreaser such as Motorcraft Brake Parts Cleaner, PM-4. 2. Clean transmission case casting in the area of the plug using general purpose degreaser making sure the area is free from grease and other contaminants. 3. Apply a 1/4" bead of silicone sealant F7TZ-19554-AA to plug E9TZ-7N171-A making sure that the groove in the plug is filled with silicone sealant. 4. Immediately install plug into the transmission case casting smoothing out any overflow that may occur during installation. PART NUMBER PART NAME PM-4 Motorcraft Brake Parts Cleaner E9TZ-7N171-A Plug - Converter Access F7TZ-19554-AA Ultra Silicone Sealant OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 022101A Install Torque Converter 0.2 Hr. Access External Dust Plug - 1989-1996 Bronco, 1989-1997 F-150, F250LD, F-Super Duty, E-Series, Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Customer Interest: > 02-21-1 > Oct > 02 > A/T - Torque Converter Access Plug Dislodges > Page 5694 1998-2003 F-150, Lightning, Harley Davidson, F-250LD, Super Duty F-Series, E-Series, 2000-2003 Excursion, 1989-2003 Motor Home Stripped Chassis, 1997-2003 Expedition, Navigator, 2002-2003 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 7N171 39 OASIS CODES: 504000 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-21-1 > Oct > 02 > A/T - Torque Converter Access Plug Dislodges Torque Converter: All Technical Service Bulletins A/T - Torque Converter Access Plug Dislodges Article No. 02-21-1 10/28/02 TRANSMISSION - 4R100/E4OD - TORQUE CONVERTER ACCESS EXTERNAL DUST PLUG MAY BECOME DISLODGED FORD: 1989-1996 BRONCO 1989-1997 F SUPER DUTY 1989-1998 F-250 LD, F-53 MOTORHOME 1989-2003 E SERIES, F-150 1997-2003 EXPEDITION 1999-2003 SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2000-2003 EXCURSION LINCOLN: 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD ISSUE Some vehicles equipped with the E4OD/4R100 transmission may exhibit the torque converter external access dust plug dislodging and falling out during severe duty use. This may be caused by a combination of stack up tolerance, material shrinkage over time and loading being applied to the plug during usage or cleaning of the underside of the vehicle. ACTION Obtain new plug (E9TZ-7N171-A) and apply 1/4" bead of silicone sealant around entire perimeter of part and install plug into transmission case. The silicone is to be applied in the groove of the part such that when it is installed, the sealant will till any gaps between the transmission case and the plug. SERVICE PROCEDURE 1. Obtain service part E9TZ-7N171-A, F7TZ-19554-AA and general purpose degreaser such as Motorcraft Brake Parts Cleaner, PM-4. 2. Clean transmission case casting in the area of the plug using general purpose degreaser making sure the area is free from grease and other contaminants. 3. Apply a 1/4" bead of silicone sealant F7TZ-19554-AA to plug E9TZ-7N171-A making sure that the groove in the plug is filled with silicone sealant. 4. Immediately install plug into the transmission case casting smoothing out any overflow that may occur during installation. PART NUMBER PART NAME PM-4 Motorcraft Brake Parts Cleaner E9TZ-7N171-A Plug - Converter Access F7TZ-19554-AA Ultra Silicone Sealant OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 022101A Install Torque Converter 0.2 Hr. Access External Dust Plug - 1989-1996 Bronco, 1989-1997 F-150, F250LD, F-Super Duty, E-Series, Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-21-1 > Oct > 02 > A/T - Torque Converter Access Plug Dislodges > Page 5700 1998-2003 F-150, Lightning, Harley Davidson, F-250LD, Super Duty F-Series, E-Series, 2000-2003 Excursion, 1989-2003 Motor Home Stripped Chassis, 1997-2003 Expedition, Navigator, 2002-2003 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 7N171 39 OASIS CODES: 504000 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Torque Converter: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Four Wheel Drive Indicator Lamp: All Technical Service Bulletins Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Torque Converter: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 5706 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > All Other Service Bulletins for Torque Converter: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 5712 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications > 4R70W Torque Converter: Specifications Stall Speed K Factor 165 rpm Min 2200 rpm Max 2500 rpm End Play New 0.355-1.04 mm Used 0.355-1.87 mm Torque Converter Drain Plug 28-30 Nm Torque Converter Nuts 27-46 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Specifications > 4R70W > Page 5715 Torque Converter: Specifications Torque Converter Drain Plug 24-27 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 4R70W Torque Converter: Description and Operation 4R70W The torque converter transmits and multiplies torque. The torque converter is a four-element device: impeller assembly - turbine assembly - reactor assembly - clutch and damper assembly The standard torque converter components operate as follows: Rotation of the converter housing and impeller set the fluid in motion. - The turbine reacts to the fluid motion from the impeller, transferring rotation to the geartrain through the input shaft. - The reactor redirects fluid going back into the impeller, allowing for torque multiplication. - The clutch and damper assembly dampens powertrain torsional vibration and provides a direct mechanical connection for improved efficiency. - Power is transmitted from the torque converter to the planetary gearsets and other components through the input shaft. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Description and Operation > 4R70W > Page 5718 Torque Converter: Description and Operation 4R100 The torque converter transmits and multiplies torque. The torque converter is a four-element device: impeller assembly - turbine assembly - reactor assembly - clutch and damper assembly The standard torque converter components operate as follows: Rotation of the converter housing and impeller set the fluid in motion. - The turbine reacts to the fluid motion from the impeller, transferring rotation to the geartrain through the input shaft. - The reactor redirects fluid going back into the impeller, providing for torque multiplication. - The clutch and damper assembly dampens powertrain torsional vibration and provides a direct mechanical connection for improved efficiency. - Power is transmitted from the torque converter to the planetary gearsets and other components through the input shaft. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Torque Converter: Initial Inspection and Diagnostic Overview 4R70W 1. If the torque converter is being replaced, continue with Substep 2 of Step 2. 2. If the torque converter is not being replaced, the following procedures must be performed: 1 The torque converter must be thoroughly cleaned. Torque converters with drain plugs can be cleaned by using Torque Converter/Oil Cooler Cleaner. - Torque converters without drain plugs can be cleaned by hand. Partially fill the torque converter using only recommended transmission fluid for the applicable transmission. Hand agitate the torque converter and then thoroughly drain the fluid. Refill the torque converter with new fluid specified for transmission, and reinstall. 2 All in-tank and auxiliary coolers must be thoroughly cleaned by forward and backward flushing. 3 All cooler lines must be thoroughly cleaned by backward and forward flushing. 4 All Cooler Bypass Valves (CBV), if equipped, must be thoroughly cleaned. 5 Perform the Transmission Fluid Cooler Flow Test. 6 If the transmission cooling system fails the Transmission Fluid Cooler Flow Test, the fluid cooler, cooler bypass valve, and/or cooler lines must be replaced. 7 If the coolers are to be replaced, use only factory approved service parts. 4R100 1. If the torque converter is being replaced, continue with sub-step 2 of Step 2. 2. If the torque converter is not being replaced the following procedures must be performed: 1 The torque converter must be thoroughly cleaned. Torque converter with drain plugs may be cleaned by using the special tool. - Torque converter without drain plugs may be cleaned by hand. Partially fill the torque converter using only the recommended transmission fluid for the applicable transmission. Hand-agitate the torque converter and then thoroughly drain the fluid. Refill the torque converter with new fluid specified for the transmission, and install. 2 NOTE: 5.4L engine applications will still use the in-tank coolers. The Oil-To-Air (OTA) cooler will be used as an auxiliary cooler for this application only. The Oil-To-Air (OTA) cooler must be replaced when contamination is present in the transmission. Do not try to clean or backflush the OTA cooler or the contamination may be reintroduced into the transmission, causing transmission assembly damage. The in-tank and auxiliary coolers must be thoroughly cleaned by forward and backward flushing. 3 The cooler lines must be thoroughly cleaned by backward and forward flushing. 4 All Cooler Bypass Valves (CBV), if equipped, must be thoroughly cleaned. 5 Perform the Transmission Fluid Cooler Flow Test. 6 If the transmission cooling system fails the Transmission Fluid Cooler Flow Test, the fluid cooler (OTA), cooler bypass valve, and or cooler lines must be replaced. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5721 Torque Converter: Component Tests and General Diagnostics Diagnosis Prior to torque converter replacement, all diagnostic procedures must be followed. This is to prevent the unnecessary replacement of good torque converters. Only after a complete diagnostic evaluation can the decision be made to replace the torque converter. Begin with the normal diagnostic procedures as follows: 1. Preliminary Inspection. 2. Know and Understand the Customer's Concern. 3. Verify the Condition-Perform the Torque Converter Operation Test. 4. Perform Diagnostic Procedures. - Run on-board diagnostics. Repair all non-transmission related DTCs first. - Repair all transmission DTCs. - Rerun on-board diagnostic to verify repair. - Perform Line Pressure Test. - Perform Stall Speed Test. - Perform Diagnostic Routines. Use the Diagnosis by Symptom index to locate the appropriate routine that best describes the symptom(s). The routine will list all possible components that may cause or contribute to the symptom. Check each component listed; diagnose and repair as required before changing the torque converter. End Play Check Special Tools 1. Insert End Play Checking Tool into the torque converter pump drive. 1 Position End Play Checking Tool. 2 Tighten the inner post until the tool is securely locked. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5722 2. Attach Dial Indicator With Bracketry to End Play Checking Tool. - Position the dial indicator bottom on the converter pump drive hub and zero the dial. 3. Lift up on End Play Checking Tool and note the dial indicator reading. - If the reading exceeds end play limits, replace the torque converter. 4. Remove the dial indicator and tool. Leakage Checks 1. Clean the outside surface of the torque converter. 2. Install Torque Converter Leak Check Tool and Gasket into convert hub. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5723 3. WARNING: Always follow proper safety procedures while using press. Install the torque converter with the installed leak check tool into the Arbor press. Secure the press. Apply enough force from the press to seal tool into the torque converter. 4. NOTE: Use clean dry shop air. Apply air pressure to valve on leak check tool. 5. With air pressure applied to valve, inspect for leaks at converter hub, seams and studs. A soap bubble solution may be applied around those areas to aid in diagnosis. If leaks are present, replace converter. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5724 6. Remove air hose. Release pressure and then slowly release press. Remove converter. Remove tool. Operation Test This test verifies that the torque converter clutch control system and the torque converter are operating properly. 1. Perform Quick Test. Check for DTCs. 2. Connect a tachometer to the engine. 3. Bring the engine to normal operating temperature by driving the vehicle at highway speeds for approximately 15 minutes in (D) position. 4. After normal operating temperature is reached, maintain a constant vehicle speed of about 80 km/h (50 mph) and tap brake pedal with the left foot. 5. Engine rpm should increase when brake pedal is tapped, and decrease about five seconds after pedal is released. If this does not occur, refer to Torque Converter Operation Concerns in the Diagnosis by Symptom Chart. 6. If the vehicle stalls in (D) or manual 2 at idle with vehicle at a stop, move the transmission range selector lever to manual 1 position. If the vehicle stalls, refer to Torque Converter Operation Concerns. Repair as required. If the vehicle does not stall in (D) refer to Diagnosis by Symptom. Part 1 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5725 Part 2 Of 2 7. If the vehicle exhibits a vibration during the road test complete the Road Test Evaluation Form. This form will aid the technician in determining the source of the vibration. NOTE: The following is a list of common vehicle concerns that have been misdiagnosed as torque converter clutch shudder. a. spark plugs-check for cracks, high resistance or broken insulators b. plug wires c. fuel injector-filter may be plugged d. fuel contamination-poor engine performance e. EGR valve-valve may let in too much exhaust gas and cause engine to run lean f. vacuum leak-engine will not get proper air/fuel mixture g. MAP/MAF sensor-improper air/fuel mixture h. H02S sensor-too rich/lean air/fuel mixture i. fuel pressure-may be too low j. engine mounts-loose/damaged mounts can cause vibration concerns k. axle joints-check for vibration Stator to Impeller Interference Check 1. NOTE: Front pump support may remain in front pump support and gear during this test. Position the front pump support with the splines up. 2. Mount (A) torque converter on the (B) front pump support with the splines on the one-way clutch inner race, engaging the mating splines of the front pump support. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5726 3. Hold the (A) front pump support stationary and rotate the (B) torque converter counterclockwise. - The torque converter should rotate freely with no signs of scraping. - If there are signs of scraping, replace the torque converter. Stator to Turbine Interference Check 1. NOTE: Front pump support may remain in front pump support and gear during this test. Position the torque converter with the pump drive up. 2. Install the (A) front pump support to engage the mating splines of the front pump support shaft on the (B) torque converter. 3. Install the forward clutch cylinder and shaft engaging the splines with the rear clutch hub. 4. Check for stator to turbine interference. 1 Hold the front pump support stationary. 2 Attempt to rotate the forward clutch cylinder and shaft. The turbine and torque converter clutch assemblies should rotate in both directions not exceeding maximum torque of 9.5 Nm (7 ft. lbs.) without any signs of metallic interference or scraping noise. 5. If interference exists, the stator front thrust washer may be worn, allowing the stator to hit the turbine. In such cases, the torque converter must be replaced. The converter crankshaft pilot should be checked for nicks or damaged surfaces that could cause interference when installing the torque converter into the crankshaft. Check the converter front impeller hub for nicks or sharp edges that would damage the pump seal. End Play Check Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5727 Special Tools 1. Install the End Play Checking Tool. 1 Insert the End Play Checking Tool fully into the torque converter pump drive. 2 Tighten until the inner post of tool is securely locked. 2. Attach the Dial Indicator with Bracketry to the End Play Checking Tool. - Position the (A) indicator button between the ridges on the converter housing and zero the (B) dial. 3. Lift up on the End Play Checking Tool as far as it will move and note the dial indicator reading. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5728 Torque Converter End Play - If the reading exceeds end play limits, replace the torque converter. 4. Remove the dial indicator and tool. Leakage Checks Special Tools 1. Clean the outside surface of the torque converter. 2. Install the Torque Converter Leak Check Tool and Gasket into the converter hub. 3. WARNING: Always follow proper safety procedures while using the press. Install the torque converter with the installed leak check tool into the Arbor press. Secure the press. Apply enough force from the press to sea] the tool into the torque converter. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5729 4. NOTE: Use clean, dry shop air. Apply air pressure to the valve on the leak check tool. 5. With air pressure applied to the valve, inspect for leaks at the converter hub, the seams and the studs. A soap bubble solution can be applied around those areas to aid in the diagnosis. If any leaks are present, replace the converter. 6. Remove the air hose. Release the pressure, and then slowly release the press. Remove the converter. Remove the tool. Stator to Impeller Interference Check 1. CAUTION: To perform this check, do not use the pump stator support which will be installed in the transmission. Damage to the pump stator support, front pump seal or front pump stator seal may occur. NOTE: Obtain a scrapped pump. Remove the stator support, This can be used as a permanent tool to perform this check. Position the stator support with the splines up. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5730 2. Mount the (A) torque converter on the (B) stator support so that the splines on the one-way clutch inner race engage the mating splines of the stator support. 3. Hold the stator support stationary and rotate the torque converter counterclockwise. - The torque converter should rotate freely, with no signs of scraping. - If there are signs of scraping, replace the torque converter. Stator to Turbine Interference Check 1. Position the torque converter with the converter hub up. 2. Install a pump stator support, engaging the mating splines of the stator support shaft. 3. Install the input shafts, engaging the splines with the turbine hub. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5731 4. Hold the stator support stationary and attempt to rotate the turbine with the input shafts. - The turbine and lockup clutch assemblies should rotate in both directions, without any signs of interference or metallic scraping noise. 5. If interference exists, the stator front thrust washer may be worn, allowing the stator to hit the turbine. In such cases, the torque converter must be replaced. Check the converter crankshaft pilot for nicks or damaged surfaces that could cause interference when installing the torque converter into the crankshaft pilot. Check the converter front impeller hub for nicks or sharp edges that would damage the pump seal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Service and Repair > 4R70W Torque Converter: Service and Repair 4R70W Flushing NOTE: When the transmission has been repaired for internal damage the torque converter must be cleaned using a mechanically agitated cleaner. 1. Use Torque Converter/Oil Cooler Cleaner to clean and flush the torque converter. 2. After flushing, drain the remainder of the solvent. 3. Add 1.9 liter (2 quart) of clean transmission fluid to the converter and agitate by hand. 4. Thoroughly drain the solution. Service and Replacement 1. The torque converter must be replaced if one or more of the following statements are true: - A torque converter malfunction has been determined based on complete diagnostic procedures. - Converter studs (5), impeller hub or bushing are damaged. - Discoloration (due to overheating). - The torque converter is found to be out of specification when performing one of the following torque converter checks: One-Way Clutch Check - End Play Check - Stator to Turbine Interference Check - Stator to Impeller Interference Check - Torque Converter Leak Check - Evidence of transmission assembly or fluid contamination due to the following transmission or converter failure modes: Major Metallic Failure - Multiple Clutches or Clutch Plate Failures - Sufficient Component Wear which results in Metallic Contamination Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Service and Repair > 4R70W > Page 5734 Torque Converter: Service and Repair 4R100 Flushing 1. CAUTION: Mineral spirits used to clean the torque converter must be fresh, non-chlorinated and non-halogenated. Following the instructions included with the Torque Converter/Transmission Oil Cooler Cleaner, flush the torque converter. 2. After flushing, drain the remainder of the solvent through the converter drain plug. 3. Add 1.9 liter (2 quart) of clean Motorcraft MERCON Multi-Purpose (ATF) Transmission Fluid XT-2-QDX or equivalent Meeting MERCON specification approved fluid into the converter fluid filler tube and agitate by hand. MERCON(R) automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4. 4. Thoroughly drain the solution. Service and Replacement 1. The torque converter must be replaced if one or more of the following statements are true: - A torque converter malfunction has been determined based on the complete diagnostic procedures. - Converter stud(s), impeller hub or bushing is damaged. - Discoloration of the torque converter (due to overheating). - The torque converter is found to be out of specification when performing one of the following torque converter checks: One-Way Clutch Check - End Play Check - Stator to Turbine Interference Check - Stator to Impeller Interference Check - Torque Converter Leak Check - Evidence of transmission assembly or fluid contamination due to the following transmission or converter failure modes: major metallic failure - multiple clutches or clutch plate failures - sufficient component wear which results in metallic contamination. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Tools and Equipment > 4R70W Torque Converter: Tools and Equipment 4R70W Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Tools and Equipment > 4R70W > Page 5737 Torque Converter: Tools and Equipment 4R100 Special Tools Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Testing and Inspection > 4R70W Torque Converter Clutch: Testing and Inspection 4R70W Special Tools 1. Insert Converter Clutch Holding Tool in one of the grooves in the stator thrust washer. 2. Install Converter Clutch Torquing Tool in the converter pump drive. 3. Use a (A) torque wrench to turn (B) Converter Clutch Torquing Tool counterclockwise while holding the (C) Converter Clutch Holding Tool. - The converter should lock up and hold torque. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Testing and Inspection > 4R70W > Page 5742 - The torque converter one-way clutch should rotate freely in the clockwise direction. - Try the clutch for lockup and hold in at least five positions. - If the torque converter fails the lockup test torque, replace the torque converter. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Testing and Inspection > 4R70W > Page 5743 Torque Converter Clutch: Testing and Inspection 4R100 Special Tools 1. Insert the Converter Clutch Holding Tool in one of the grooves in the stator thrust washer. 2. Install the Converter Clutch Torquing Tool in the converter pump drive. 3. Using (A) torque wrench, turn the (B) Converter Clutch Torquing Tool counterclockwise while holding the (C) Converter Clutch Holding Tool. - The converter one-way clutch should lock up and hold the specified torque. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Testing and Inspection > 4R70W > Page 5744 - The torque converter one-way clutch should rotate freely in the clockwise direction. - Try the clutch for lockup and hold in at least five positions. - If the clutch fails to lock up and hold the specified torque, replace the torque converter. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch, A/T > Component Information > Testing and Inspection > Page 5745 Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications TCC Solenoid Bolt 9-11 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator Transmission Cooler: Customer Interest A/T Cooler - Fluid Leaks at Radiator Article No. 00-9-1 DATE 5/1/00 TITLE LEAK - TRANSMISSION FLUID LEAKS AT RADIATOR - VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSION AND TRANSMISSION OIL COOLER IN RADIATOR END TANK FORD: 1997-2000 MUSTANG, EXPEDITION, EXPLORER, F-150, F-250 LD 1998-2000 RANGER 1999-2000 SUPER DUTY F SERIES LINCOLN: 1998-2000 NAVIGATOR MERCURY: 1998-2000 MOUNTAINEER This TSB is being republished in its entirety to update the vehicles affected and to update the Service Procedure. ISSUE Transmission fluid may leak between the radiator transmission oil cooler and the transmission oil cooler fitting (NOT the cooler line into the fitting), which may result in a residue of transmission fluid on the radiator tank around the transmission oil cooler fitting. This may be caused by insufficient thread sealer on the transmission oil cooler fitting. NOTE: THIS TSB DOES NOT APPLY TO TRANSMISSION FLUID LEAKAGE AT THE TRANSMISSION LINE TO TRANSMISSION OIL COOLER FITTING. ACTION Install O-ring W705181-S onto the transmission oil cooler fitting. The O-ring is designed to seal the leak and reduce the possibility of transmission fluid leakage. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify that transmission fluid is leaking between the transmission oil cooler and the transmission oil cooler fitting (NOT the transmission cooler line fitting into the transmission oil cooler fitting). Refer to Figure 1. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 5757 2. Remove the radiator from the vehicle following Workshop Manual procedure. Place the radiator on a flat surface so that the transmission oil cooler fittings are facing upward. Refer to Figure 2. 3. Clean the area around the transmission oil cooler fitting. This will insure that contaminants do not enter the transmission oil cooler when the transmission oil cooler fittings are removed. CAUTION: OIL-BASED SOLVENTS AND CLEANERS SHOULD NOT BE USED WHEN CLEANING THE RADIATOR. OIL-BASED SOLVENTS AND CLEANERS CAN DAMAGE THE RADIATOR END TANK SEALS AND CAUSE LEAKS. 4. Remove the upper transmission oil cooler fitting. NOTE: REMOVE ONLY ONE (1) TRANSMISSION OIL COOLER FITTING AT A TIME, OTHERWISE THE COOLER MAY DROP INTO THE RADIATOR. 5. Once the fitting is removed from the transmission oil cooler, verify that there is a gasket between the transmission oil cooler and the inside of the radiator tank. If there is no gasket, replace the radiator. If the gasket is in place, continue to Step 6. 6. Inspect the transmission oil cooler fitting threads for damage. If the threads are damaged, replace the radiator. If the threads show no sign of damage, continue to Step 7. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 5758 7. Install O-ring W705181-S on the transmission oil cooler fitting. Refer to Figures 2 and 3. CAUTION: THREAD SEALANT OR TAPE SHOULD NEVER BE USED ON THE THREADS OF THE TRANSMISSION OIL COOLER FITTING. THE USE OF SUCH MATERIALS WILL CREATE A LEAK PATH. 8. Making sure that the gasket between the transmission oil cooler and the inside of the radiator tank is still in place, reinstall the transmission oil cooler fitting. The fitting should be torqued to 38-45 N.m (28-33 lb-ft). NOTE:: DO NOT USE AIR TOOLS TO TORQUE THE TRANSMISSION OIL COOLER FITTING. USE A HAND-OPERATED TORQUE WRENCH ONLY. 9. Repeat Steps 2-8 for the other transmission oil cooler fitting. This fitting should also have the O-ring replaced even if it is not leaking. 10. Make sure that no radiator coolant has entered the transmission oil cooler. Reinstall the radiator in the vehicle following Workshop Manual procedure. 11. Verify that both the transmission and the engine cooling system have the proper fluid levels outlined in the Workshop Manual. PARTS INFORMATION LABOR OPERATION APPLICATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 5759 OTHER APPLICABLE ARTICLES: NONE SUPERCEDES: 99-4-6 WARRANTY STATUS OPERATION DESCRIPTION DEALER CODING OASIS CODES: 402000, 510000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-14-8 > Jul > 03 > A/T - Cooler Flushing Service Tips Transmission Cooler: All Technical Service Bulletins A/T - Cooler Flushing Service Tips Article No. 03-14-8 07/21/03 TRANSMISSION - NEW TRANSMISSION COOLER FLUSHER - SERVICE TIPS FORD: 1992-1997 CROWN VICTORIA, PROBE, THUNDERBIRD 1992-2003 ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1992-1996 BRONCO 1992-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1992-1999 F-250 LD 1992-2003 ECONOLINE, EXPLORER, F-150, RANGER 1995-2003 WINDSTAR 1997-2003 EXPEDITION 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1992-1997 TOWN CAR 1992-2002 CONTINENTAL 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD 2003 AVIATOR MERCURY: 1992-1997 COUGAR, GRAND MARQUIS 1992-2000 TRACER 1992-2003 SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER This article supersedes TSB 00-1-5. ISSUE The number one cause for repeat transmission repairs is that contamination from the transmission cooler system (lines and tank) will work their way back into the rebuilt or new transmission. For this reason a new transmission cooler flusher has been released, "Turbo-Tank Heated Cooler Line Flusher" Rotunda Tool number 22-00001. ACTION The transmission cooling system (cooler and lines) MUST be flushed every time the transmission is overhauled or replaced in order to minimize the likelihood of repeat repairs. The use of this new "Turbo-Tank Heated Cooler Line Flusher" (222-00001) is the most effective way to remove contamination from its cooling system. Refer to the following Service Procedure and Equipment instructions (supplied with the "Turbo-Tank Heated Cooler Line Flusher"). SERVICE PROCEDURE Prior methods of cooler flushing have not obtained the level of cooler cleaning and contaminant removal that is required to prevent repeat repairs. The "Turbo-Tank Heated Cooler Line Flusher" uses heated Automatic Transmission Fluid (ATF) and a pulsating action to loosen system contamination. Previous equipment used solvents to clean & flush coolers, lines and torque-converters. There are 2 issues with this method: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-14-8 > Jul > 03 > A/T - Cooler Flushing Service Tips > Page 5765 ^ Residual solvent contamination can cause damage to friction bonding materials within the transmission (Clutches and Bands). ^ Lack of fluid heating and agitation prevents this method from completely removing contamination from lines, in-radiator coolers and auxiliary coolers. Aerosol Solvents should never be used for several reasons. ^ They do not provide the volume necessary to remove heavy contaminants. ^ They evaporate quickly and essentially leave contaminants in pockets, bends, or wherever they are as the solvent dries. NOTE YOU MUST IDENTIFY THE RETURN COOLER LINE TO START THE BACK FLUSHING PROCEDURE. A quick way to identify the return cooler line (fluid coming out of the cooler and returning to the transmission) is to locate the return cooler line fitting on the transmission case. Refer to the following lists: Rear Wheel Drive ^ TORQSHIFT, 4R100, E40D, C6 - The REAR transmission case filling receives the return line. ^ 4R70W, AODE, AOD - The TOP transmission case filling receives the return line. ^ A4LD, 4R44/55E, 5R55E, 5R55N, 5R55W, 5R55S - The TOP transmission case filling receives the return line. Front Wheel Drive ^ CD4E - The REAR or Pump End transaxle case fitting receives the return line. ^ 4F27E - The REAR or Cover End transaxle case fitting receives the return line. ^ AXOD, AXODE, AX4S, AX4N, 4F50N - The BOTTOM transaxle cooler line fitting receives the return line. NOTE IF AN IN-LINE FILTER HAS BEEN INSTALLED IN THE COOLER LINE, IT MUST BE REMOVED BEFORE FLUSHING THE COOLER OR COOLER LINES. Purge the cooler and cooler line before flushing: Located on the "Turbo-Tank Heated Cooler Line Flusher" is a fluid transfer and purge valve. This valve can be used to purge the cooler and cooler lines of contaminated fluid before starting the back flush procedure of the fluid cooling system (refer to step 5a of this Service Procedure or Equipment instructions, supplied with the "Turbo-Tank Heated Cooler Line Flusher"). Flush Procedure 1. Check and top off fluid level of the "Turbo-Tank Heated Cooler Line Flusher" tank with transmission fluid. 2. Allow the fluid in the flusher 15-30 minutes to heat up to 140° F (60° C) before using. 3. Install line adapters into the transmission cooler lines. 4. Attach the flusher's blue line to the transmission return cooler line quick disconnect. 5. Attach the flusher's red line to the transmission outlet cooler line quick disconnect. a. Follow equipment instructions, to purge cooler lines and cooler prior to starting flushing procedure (using factory installed purge valve and clear hose on "Turbo-Tank Heated Cooler Line Flusher"). 6. Allow the cooling system to back-flush for 10-15 minutes, then flush the cooler in a forward/normal flow direction for an additional 10-15 minutes. For ordering information on this new "Turbo-Tank Heated Cooler Line Flusher" (222-00001), contact Rotunda at 800-ROTUNDA (800-768-8632 or outside U.S. 262-656-5805). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 03-14-8 > Jul > 03 > A/T - Cooler Flushing Service Tips > Page 5766 CAUTION THIS FLUSHER CANNOT BE USED TO FLUSH COOLERS ON VEHICLES EQUIPPED WITH THE TEMPERATURE BYPASS-TYPE TRANSMISSION COOLER CURRENTLY FOUND IN 1998-2003 CROWN VICTORIA, GRAND MARQUIS, AND TOWN CAR VEHICLES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-1-5 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-9-1 > May > 00 > A/T Cooler Fluid Leaks at Radiator Transmission Cooler: All Technical Service Bulletins A/T Cooler - Fluid Leaks at Radiator Article No. 00-9-1 DATE 5/1/00 TITLE LEAK - TRANSMISSION FLUID LEAKS AT RADIATOR - VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSION AND TRANSMISSION OIL COOLER IN RADIATOR END TANK FORD: 1997-2000 MUSTANG, EXPEDITION, EXPLORER, F-150, F-250 LD 1998-2000 RANGER 1999-2000 SUPER DUTY F SERIES LINCOLN: 1998-2000 NAVIGATOR MERCURY: 1998-2000 MOUNTAINEER This TSB is being republished in its entirety to update the vehicles affected and to update the Service Procedure. ISSUE Transmission fluid may leak between the radiator transmission oil cooler and the transmission oil cooler fitting (NOT the cooler line into the fitting), which may result in a residue of transmission fluid on the radiator tank around the transmission oil cooler fitting. This may be caused by insufficient thread sealer on the transmission oil cooler fitting. NOTE: THIS TSB DOES NOT APPLY TO TRANSMISSION FLUID LEAKAGE AT THE TRANSMISSION LINE TO TRANSMISSION OIL COOLER FITTING. ACTION Install O-ring W705181-S onto the transmission oil cooler fitting. The O-ring is designed to seal the leak and reduce the possibility of transmission fluid leakage. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify that transmission fluid is leaking between the transmission oil cooler and the transmission oil cooler fitting (NOT the transmission cooler line fitting into the transmission oil cooler fitting). Refer to Figure 1. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-9-1 > May > 00 > A/T Cooler Fluid Leaks at Radiator > Page 5771 2. Remove the radiator from the vehicle following Workshop Manual procedure. Place the radiator on a flat surface so that the transmission oil cooler fittings are facing upward. Refer to Figure 2. 3. Clean the area around the transmission oil cooler fitting. This will insure that contaminants do not enter the transmission oil cooler when the transmission oil cooler fittings are removed. CAUTION: OIL-BASED SOLVENTS AND CLEANERS SHOULD NOT BE USED WHEN CLEANING THE RADIATOR. OIL-BASED SOLVENTS AND CLEANERS CAN DAMAGE THE RADIATOR END TANK SEALS AND CAUSE LEAKS. 4. Remove the upper transmission oil cooler fitting. NOTE: REMOVE ONLY ONE (1) TRANSMISSION OIL COOLER FITTING AT A TIME, OTHERWISE THE COOLER MAY DROP INTO THE RADIATOR. 5. Once the fitting is removed from the transmission oil cooler, verify that there is a gasket between the transmission oil cooler and the inside of the radiator tank. If there is no gasket, replace the radiator. If the gasket is in place, continue to Step 6. 6. Inspect the transmission oil cooler fitting threads for damage. If the threads are damaged, replace the radiator. If the threads show no sign of damage, continue to Step 7. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-9-1 > May > 00 > A/T Cooler Fluid Leaks at Radiator > Page 5772 7. Install O-ring W705181-S on the transmission oil cooler fitting. Refer to Figures 2 and 3. CAUTION: THREAD SEALANT OR TAPE SHOULD NEVER BE USED ON THE THREADS OF THE TRANSMISSION OIL COOLER FITTING. THE USE OF SUCH MATERIALS WILL CREATE A LEAK PATH. 8. Making sure that the gasket between the transmission oil cooler and the inside of the radiator tank is still in place, reinstall the transmission oil cooler fitting. The fitting should be torqued to 38-45 N.m (28-33 lb-ft). NOTE:: DO NOT USE AIR TOOLS TO TORQUE THE TRANSMISSION OIL COOLER FITTING. USE A HAND-OPERATED TORQUE WRENCH ONLY. 9. Repeat Steps 2-8 for the other transmission oil cooler fitting. This fitting should also have the O-ring replaced even if it is not leaking. 10. Make sure that no radiator coolant has entered the transmission oil cooler. Reinstall the radiator in the vehicle following Workshop Manual procedure. 11. Verify that both the transmission and the engine cooling system have the proper fluid levels outlined in the Workshop Manual. PARTS INFORMATION LABOR OPERATION APPLICATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-9-1 > May > 00 > A/T Cooler Fluid Leaks at Radiator > Page 5773 OTHER APPLICABLE ARTICLES: NONE SUPERCEDES: 99-4-6 WARRANTY STATUS OPERATION DESCRIPTION DEALER CODING OASIS CODES: 402000, 510000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Cooler: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold Rocker Arm Assembly: All Technical Service Bulletins Engine - Rough Idle/Noise When Cold Article No. 00-26-1 12/25/00 ^ ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 ^ NOISE - FROM ENGINE - ROUGH IDLE/MISS AFTER START-UP DURING COLD AMBIENT TEMPERATURES LESS THAN - 12 DEGREES C (10 DEGREES F) - VEHICLES BUILT 3/1/1996 THROUGH 7/31/2000 FORD: 1997-1999 F-250 LD 1997-2000 ECONOLINE, EXCURSION, EXPEDITION, F-150 1999-2000 F SUPER DUTY LINCOLN: 1998-1999 NAVIGATOR ISSUE Some vehicles equipped with a 4.6L, 5.4L, or 6.8L engine may exhibit a rough idle/miss after start-up in cold ambient temperatures (less than -12°C/10 ° F). This may be caused by a roller finger follower(s) being dislodged from the valve. This may result in damage to the camshaft, roller finger follower, valve, retainer, etc. A procedure is now available to service this condition. ACTION Inspect and replace any worn or damaged engine valve components and install new retaining clip and lash adjuster for service. Refer to the following Service Procedure for details. SERVICE PROCEDURE Perform normal engine diagnostic routines before opening valve covers. If the valve train is suspect, remove the valve covers and look for Roller Finger Follower(s) (RFF) that may have become dislodged. 1. Inspect the following parts that may have been damaged by any dislodged roller finger followers: ^ Cam lobes (chipped or grooved) ^ Valve stem tips (mushroomed, metal displaced, or bent) ^ Roller finger followers (chipped or grooved) ^ Inspect valve guide only if its corresponding RFF or valve stem tip is damaged. Replace damaged parts as necessary. 2. If follower(s) are damaged, replaced as necessary, otherwise re-use followers in same location as removed from head. 3. Remove all intake and exhaust lash adjusters from the engine and replace with service-only Lash Adjusters (YL3Z-6500-AA). Refer to the appropriate workshop Manual, Section 303-01B for service procedures and tooling necessary to compress the valve springs and remove the roller followers. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Cooler: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 5779 NOTE REFER TO FIGURE 1 FOR INSTALLATION OF THE NEW RETAINING CLIPS (YL3Z-6A539-AA), TO THE ROLLER FINGER FOLLOWER. 4. Using a valve spring compression tool, install followers and the attached retaining clips by pushing clips onto lash adjuster. NOTE THE CLIP IS NOT REMOVABLE FROM ADJUSTER ONCE IT HAS BEEN SNAPPED INTO PLACE. IF THE ENGINE NEEDS TO BE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Cooler: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 5780 SERVICED AT A LATER DATE, REMOVE THE RFF BY BENDING UP THE CLIP. LEAVE LASH ADJUSTER IN THE ENGINE WITH THE CLIP WHILE REMOVING THE FOLLOWER. THEN REMOVE THE LASH ADJUSTER FROM THE HEAD AND SNIP/CUT THE CLIP FROM THE LASH ADJUSTER. REPLACE WITH A NEW CLIP ON FOLLOWER DURING INSTALLATION. 5. Check valve train for proper assembly and reinstall valve covers as outlined in the Workshop Manual, Section 303-01B. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 497000, 499000, 602300, 608000, 608400, 609000, 609400, 613000, 613500, 702000, 702100 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Cooler: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 5786 NOTE REFER TO FIGURE 1 FOR INSTALLATION OF THE NEW RETAINING CLIPS (YL3Z-6A539-AA), TO THE ROLLER FINGER FOLLOWER. 4. Using a valve spring compression tool, install followers and the attached retaining clips by pushing clips onto lash adjuster. NOTE THE CLIP IS NOT REMOVABLE FROM ADJUSTER ONCE IT HAS BEEN SNAPPED INTO PLACE. IF THE ENGINE NEEDS TO BE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Cooler: > 00-26-1 > Dec > 00 > Engine - Rough Idle/Noise When Cold > Page 5787 SERVICED AT A LATER DATE, REMOVE THE RFF BY BENDING UP THE CLIP. LEAVE LASH ADJUSTER IN THE ENGINE WITH THE CLIP WHILE REMOVING THE FOLLOWER. THEN REMOVE THE LASH ADJUSTER FROM THE HEAD AND SNIP/CUT THE CLIP FROM THE LASH ADJUSTER. REPLACE WITH A NEW CLIP ON FOLLOWER DURING INSTALLATION. 5. Check valve train for proper assembly and reinstall valve covers as outlined in the Workshop Manual, Section 303-01B. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 497000, 499000, 602300, 608000, 608400, 609000, 609400, 613000, 613500, 702000, 702100 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Page 5788 Transmission Cooler: Specifications Auxiliary Transmission Fluid Cooler Bolts 6 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Locations > 4R70W Transmission Cooler: Locations 4R70W W/O Auxiliary Cooler Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Locations > 4R70W > Page 5791 With Auxiliary Cooler Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Locations > 4R70W > Page 5792 Transmission Cooler: Locations 4R100 W/O Auxiliary Cooler Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Locations > 4R70W > Page 5793 With Auxiliary Cooler Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Locations > Page 5794 Transmission Cooler: Description and Operation All vehicles with automatic transmissions are equipped with an integral transmission fluid cooler. The integral transmission fluid cooler is contained inside of the radiator outlet tank and cannot be serviced separately. Some vehicles are equipped with an optional auxiliary transmission fluid cooler that is mounted in front of the radiator. In operation, transmission fluid travels from the transmission to the auxiliary transmission fluid cooler, if equipped, to the integral transmission fluid cooler then back to the transmission. The integral transmission fluid cooler transfers heat from the transmission fluid to the engine coolant. The auxiliary transmission fluid cooler transfers heat from the transmission fluid to outside air. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Testing and Inspection > Flow of Diagnosis Transmission Cooler: Flow of Diagnosis When fluid leakage is found at the radiator outlet tank, the radiator outlet tank must be replaced. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 5797 Transmission Cooler: Initial Inspection and Diagnostic Overview When fluid leakage is found at the radiator outlet tank, the radiator outlet tank must be replaced. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Testing and Inspection > Flow of Diagnosis > Page 5798 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Oil Cooler, Transmission Transmission Cooler: Service and Repair Oil Cooler, Transmission Backflush/Cleaning 1. Conduct backflushing with a Torque Converter/Oil Cooler Cleaner. Test your equipment to make sure that a vigorous fluid flow is present before proceeding. Replace the system filter if flow is weak or contaminated. 2. To aid in attaching the cleaner to the transmission steel cooler lines, connect two additional rubber hoses to the transmission end of the steel transmission cooler lines. Connect the cleaner tank pressure line to the steel transmission cooler return line (longest line). - Connect a tank return hose to the steel transmission cooler pressure line (shorter line). Place the outlet end of this hose in the solvent tank reservoir. 3. Turn on solvent pump and allow the solvent to circulate a minimum of 5 minutes (cycling switch on and off will help dislodge contaminants in cooler system). 4. Switch off the solvent pump and disconnect the solvent pressure hose from the transmission cooler return line. 5. Use compressed air to blow out the cooler(s) and lines (blow air into the transmission cooler return line) until all solvent is removed. 6. Remove the rubber return hose from the remaining steel cooler line. Removal and Installation Removal 1. Remove the front skid plate. 1 Remove the bolts. 2 Remove the front skid plate. 2. Place a drain pan under the auxiliary transmission fluid cooler. 3. Remove the auxiliary transmission fluid cooler. 1 Disconnect the two auxiliary transmission fluid cooler tubes. 2 Remove the bolts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Oil Cooler, Transmission > Page 5801 3 Remove the auxiliary transmission fluid cooler. Installation 1. Follow the removal procedure in reverse order. Backflushing and Cleaning CAUTION: Test the Torque Converter/Oil Cooler Cleaner to ensure that a vigorous fluid flow is present before proceeding. Replace the system filter if flow is weak or contaminated. 1. NOTE: Rubber hoses must be attached to the ends of the fluid cooler tubes, to aid in connecting them to the cleaner. Connect the cleaner pressure and return lines appropriately. 1 Connect the pressure line to fluid cooler inlet tube. 2 Connect the return line to fluid cooler outlet tube. 3 Place the outlet end of the return line in the solvent tank reservoir. 2. NOTE: Cycling the solvent pump on and off will help dislodge contaminants in the cooler system. Switch the solvent pumps on. Allow the solvent to circulate a minimum of 5 minutes. 3. Switch the solvent pump off. 4. Disconnect the cleaner pressure line at the fluid cooler tube. 5. Using compressed air, blow through the fluid cooler inlet tube until all solvent is removed. 6. Remove the rubber hoses from fluid cooler tubes. Removal and Installation Removal Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Oil Cooler, Transmission > Page 5802 1. Remove the front skid plate. 1 Remove the bolts. 2 Remove the front skid plate. 2. Place a drain pan under the auxiliary transmission fluid cooler. 3. Remove the auxiliary transmission fluid cooler. 1 Disconnect the two auxiliary transmission fluid cooler tubes. 2 Remove the bolts. 3 Remove the auxiliary transmission fluid cooler. Installation 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Oil Cooler, Transmission > Page 5803 Transmission Cooler: Service and Repair Cooler Bypass Valve Removal and Installation Removal 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Remove the front cooler tube from the front Cooler Bypass Valve (CBV) fitting. 4. Remove the rear cooler tube from the rear CBV fitting. 5. NOTE: The rubber-coated sealing washers can fall off during removal of the front CBV bolt cooler line case fitting. Remove the front CBV bolt cooler case fitting. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Oil Cooler, Transmission > Page 5804 6. NOTE: The rubber coated sealing washers can fall off during removal of the rear CBV bolt cooler line case fitting. Remove the rear CBV bolt cooler line case fitting. 7. Remove, clean and flush the CBV. Installation 1. CAUTION: Make sure the 4 rubber-coated sealing washers are on the cooler line case fittings and the CBV washers are in place. Examine the rubber-coated sealing washers for damage. Replace the washers as needed. 2. Using Thread lock and Sealer E0AZ-19554-AA or equivalent meeting Ford specification WSK-M2G351-A5, coat the line case fitting threads. 3. CAUTION: Make sure the Cooler Bypass Valve (CBV) is properly back flushed. Use dry compressed air to remove solvent. CAUTION: If the cooler line case fitting is over-tightened, the rubber-coated sealing washers and/or cooler line case fittings can be damaged, causing a transmission fluid leak. NOTE: The CBV has a check ball in the rear fitting and will only allow flow in one direction. Make sure check ball moves freely. NOTE: Align the two rubber-coated sealing washers while assembling the rear cooler line case fitting. Install the CBV fitting. 4. CAUTION: If an overhaul is being performed the Oil-To-Air (OTA) cooler will need to be replaced. NOTE: The cooler lines need to be flushed out at this time and the OTA replaced. Do not backflush the Oil-To-Air (OTA) cooler. Tighten the cooler tube nuts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Oil Cooler, Transmission > Page 5805 5. Lower the vehicle. 6. Reconnect the battery ground cable. 7. Fill the transmission with Motorcraft MERCON Multi-Purpose (ATF) Transmission Fluid XT-2-QDX or equivalent Meeting MERCON specification. Check for proper operation. MERCON(R) automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4. Disassembly and Assembly Special Tools Disassembly NOTE: The cooler bypass valve needs to be thoroughly cleaned and flushed out at this time. 1. Remove and inspect the cooler line case fittings. If the cooler line case fittings are damaged replace the cooler line case fittings. 2. NOTE: Damaged sealing washers will cause transmission fluid to leak at the cooler bypass valve. Remove the rubber-coated sealing washers. Inspect the sealing washers. Replace as required. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Oil Cooler, Transmission > Page 5806 3. Inspect the sealing ends of the cooler bypass valve. If the valve assembly is damaged replace the coolant bypass valve assembly. 4. Assemble the cooler by-pass valve and plug the converter-out-to-cooler inlet with a 13 x 1.5 mm plug. 5. Place a 0.5 inch flat washer over the case converter-out fitting threads over the rubber coated sealing washer. 6. Connect the cleaner pressure line to the case converter-out fitting. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Oil Cooler, Transmission > Page 5807 7. CAUTION: Make sure the CBV is in the solvent tank before switching on the solvent pump. Also make sure the CBV fitting is pointing downward so the solvent does not spray up out of the tank. Place the CBV into the solvent tank. 8. CAUTION: The solvent pressure must be at least 344.75 kPa (50 psi) (minimum) to overcome the valve inside the CBV and let the solvent pass through it. Do not, however, exceed 620.55 kPa (90 psi) (maximum) solvent pressure. Regulate the solvent pressure. Switch on the solvent pump allowing the solvent to circulate through the CBV for 5 minutes. During this time, cycle the solvent pump on and off to help dislodge contaminants. 9. Disconnect the cleaner pressure line from the case converter-out fitting. Remove the 0.5 inch washer. 10. Using 344.75-620.55 kPa (50-90 psi) of regulated compressed air, blow through the CBV until all solvent is removed. 11. Remove the plug from the CBV converter-out-to-cooler inlet. Assembly 1. Install rubber-coated sealing washers. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Oil Cooler, Transmission > Page 5808 2. Install the cooler line case fittings. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Tools and Equipment > 4R70W Special Tool Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Tools and Equipment > 4R70W > Page 5811 Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5816 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5817 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5818 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5819 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5820 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5821 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5822 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5823 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5824 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5825 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5826 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5827 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5828 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5829 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5830 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5831 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5832 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5833 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5834 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5835 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5836 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5837 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5838 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5839 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5840 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5841 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5842 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5843 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5844 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5845 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5846 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5847 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5848 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5849 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5850 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5851 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5852 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5853 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5854 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5855 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5856 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5857 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5858 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5859 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5860 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5861 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5862 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5863 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5864 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5865 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5866 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5867 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5868 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5869 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5870 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5871 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5872 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5873 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5874 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5875 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5876 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5877 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5878 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5879 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5880 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5881 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5882 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5883 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5884 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5885 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5886 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5887 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5888 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5889 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5890 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5891 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5892 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5893 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5894 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5895 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5896 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5897 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5898 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5899 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5900 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5901 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5902 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5903 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5904 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5905 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5906 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5907 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5908 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5909 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 5910 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Specifications > 4R70W Transmission Mount: Specifications Transmission Mount Nuts 98-132 Nm Bolts 68-92 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Specifications > 4R70W > Page 5913 Transmission Mount: Specifications Transmission Insulator and Retainer to Case Bolts 81-108 Nm Transmission Insulator and Retainer to Crossmember Nuts 81-108 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > 4R70W Transmission Mount: Service and Repair 4R70W Removal 1. Raise and support the vehicle. 2. Use the High Lift Transmission Jack to support the transmission. Remove the nuts. 3. Raise the transmission enough for studs to clear the crossmember. 1 Remove the bolts. 2 Remove the transmission insulator. Installation 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > 4R70W > Page 5916 Transmission Mount: Service and Repair 4R100 Special Tools Removal NOTE: 4x2 shown, 4x4 similar. 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Remove the nuts. 4. Install the High Lift Transmission Jack with the Transmission Jack Adapter to the transmission. 5. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the TSS and OSS sensors will occur. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > 4R70W > Page 5917 Remove the rear transmission mount. 1 Raise the transmission up off the rear crossmember support. 2 Remove the bolts. 3 Remove the rear transmission mount. Installation 1. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the TSS and OSS sensors will occur. Install the rear transmission mount. 1 Raise the transmission up. 2 Install the rear transmission mount. 3 Install the bolts. 2. Lower the transmission on to the rear crossmember support. 3. Install the nuts. 4. Lower the vehicle. 5. Reconnect the battery ground cable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > 4R70W Transmission Position Switch/Sensor: Specifications Digital Transmission Range Sensor Bolts 7-10 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > 4R70W > Page 5922 Transmission Position Switch/Sensor: Specifications Digital Transmission TR Sensor 8-10 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 5923 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W Transmission Position Switch/Sensor: Service and Repair 4R70W Special Tools 1. Raise and support vehicle. 2. Disconnect the manual lever shift control cable. 3. Disconnect the digital TR electrical connector. 4. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. The old nut will not retain torque specification. Remove the manual control lever. 1 Remove the nut. 2 Remove the lever. 5. Loosen the digital TR sensor bolts. 6. NOTE: Manual shift lever must be in the neutral position. Use digital transmission range TR Sensor Alignment Tool, to align the digital TR sensor slots. The tool is designed to fit snug. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W > Page 5926 7. Tighten the bolts. 8. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual lever shaft outer nut. 9. With the manual lever in overdrive connect the shift lever control cable. 10. Install the digital TR sensor electrical connector. 11. Lower the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W > Page 5927 Transmission Position Switch/Sensor: Service and Repair 4R100 Special Tools Removal 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Disconnect the connector. 4. Disconnect the shift cable at the manual control lever. 5. Remove the digital Transmission Range (TR) sensor. 1 Remove the bolts. 2 Remove the digital Transmission Range (TR) sensor. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W > Page 5928 1. Install the digital Transmission Range (TR) sensor. 1 Install digital Transmission Range (TR) sensor. 2 Loosely install the bolts. 2. NOTE: Make sure that the manual control lever is in the neutral position. Install the Digital Transmission Range (TR) Sensor Alignment Tool. The tool is designed to fit snug. 3. Tighten the bolts. 4. Reconnect the shift cable at the manual control lever. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W > Page 5929 5. Reconnect the connector. 6. Lower the vehicle. 7. Reconnect the battery ground cable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Tools and Equipment > 4R70W Special Tool Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position Switch/Sensor, A/T > Component Information > Tools and Equipment > 4R70W > Page 5932 Special Tool Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed Sensor Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed Sensor > Page 5937 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5938 Transmission Speed Sensor: Service and Repair Removal 1. Remove the drive shaft. 2. Remove the rear transmission mount nuts. 3. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the TSS and OSS sensors will occur. Remove the rear transmission mount. 1 Raise the transmission up off the rear crossmember support. 2 Remove the bolts. 3 Remove the rear transmission mount. 4. Lower the transmission to gain access to the Turbine Shaft Speed (TSS) sensor, and the Output Shaft Speed (OSS) sensor. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5939 5. Remove the Turbine Shaft Sensor (TSS). 1 Remove the bolt. 2 Remove the Turbine Shaft Sensor (TSS). 6. Remove the Output Shaft Speed (OSS) sensor. 1 Remove the bolt. 2 Remove the Output Shaft Speed (OSS) sensor. Installation 1. Install the Output Shaft Speed (OSS) sensor. 1 Lubricate the O-ring and install the Output Shaft Speed (OSS) sensor. 2 Install the bolt. 2. Install the Turbine Shaft Sensor (TSS). 1 Lubricate the O-ring and install the Turbine Shaft Sensor (TSS). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5940 2 Install the bolt. 3. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the sensors will occur. Install the rear transmission mount. 1 Raise the transmission up. 2 Install the rear transmission mount. 3 Install the bolts. 4. Lower the transmission on to the rear crossmember support. 5. Install the rear transmission mount nuts. 6. Install the drive shaft. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > 4R70W Valve Body: Specifications Main Control Valve Body Cover Plate Bolts 9-11 Nm Main Control Valve Body Separator Plate Bolts 9-11 Nm Main Control Valve Body Bolts 9-11 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Specifications > 4R70W > Page 5945 Valve Body: Specifications Main and Lower Control Body to Case 9-11 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Diagrams > 4R70W Valve Body: Diagrams 4R70W Main Control Valve Body - Disassembled View (Part 1 Of 2) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Diagrams > 4R70W > Page 5948 Part 2 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Diagrams > 4R70W > Page 5949 Valve Body: Diagrams 4R100 Part 1 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Diagrams > 4R70W > Page 5950 2 Of 3 Part 3 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Testing and Inspection > Accumulator Body Check Valve Body: Testing and Inspection Accumulator Body Check Disassembly 1. Remove the control valves and springs. Inspect the valves for nicks and buffs. If the valves are damaged the accumulator body will need to be replaced. 2. Inspect all valves, valve sleeves, valve bores for scores, nick or burrs. Check all fluid passages for obstructions. Inspect all mating surfaces for burrs and scores. 3. Inspect all springs for distortion. Check all valves and plungers for free movement in their respective bores. All the components when dry must fall from their own weight in their respective bores. Assembly 1. Install the control valves and springs. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Testing and Inspection > Accumulator Body Check > Page 5953 Valve Body: Testing and Inspection Solenoid Body Check 1. Clean and inspect the solenoid body. - Check the connector pins for corrosion and possible bent condition. - Inspect and test the shift solenoids: refer to Pinpoint Test A. - Remove O-ring and discard. - Install new O-ring and lubricate with petroleum jelly or equivalent. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4R70W Valve Body: Service and Repair 4R70W Removal and Installation Removal 1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Drain transmission fluid and remove the transmission fluid pan and filter. 4. CAUTION: Do not pull on the plastic lead frame. This may cause damage to the connector ends. Carefully pry up on locking tabs to disconnect the solenoids. Disconnect the molded lead frame from the solenoids. Disconnect the molded lead frame from the solenoids. 1 Disconnect the shift solenoid SSA and SSB. 2 Disconnect the Torque Converter Clutch (TCC). 3 Disconnect the Electronic Pressure Control (EPC) solenoid. 4 Disconnect the bulkhead inter-connector. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4R70W > Page 5956 5. Remove the shift solenoid and the Torque Converter Clutch (TCC) solenoid. 1 Remove the bolts. 2 Remove the shift solenoid and the Torque Converter Clutch (TCC) solenoid. 6. Remove the manual valve detent spring 1 Remove the bolt. 2 Remove the manual valve detent spring 7. Remove the 23 valve body to case bolts. 8. Remove the main control valve body and discard the pump outlet screen. Installation 1. NOTE: Make sure that the drive pin of the manual valve detent lever assembly engages the manual valve in the proper location prior to installing the bolts. Position the main control valve body gasket and main control valve body using the two alignment bolts as a guide. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4R70W > Page 5957 2. NOTE: The main control valve body bolts will be tightened in later steps. Loosely install the bolts. 3. NOTE: The main control valve body bolts will be tightened in later steps. Loosely install the bolts. 4. Install the manual valve detent spring. 1 Position the manual valve detent spring. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4R70W > Page 5958 2 Install the bolt. 5. Tighten the main control valve body bolts in the sequence shown. 6. Install the shift solenoid and the Torque Converter Clutch (TCC) solenoid. 1 Install the shift solenoid and the Torque Converter Clutch (TCC) solenoid. 2 Install the bolts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4R70W > Page 5959 7. Connect the molded lead frame to the solenoids. - Connect the bulkhead inter connector. - Connect the Electronic Pressure Control (EPC) solenoid. - Connect the Torque Converter Clutch (TCC). - Connect the shift solenoid SSA and SSB. 8. CAUTION: If installing a new filter, and the grommet remains in the main control bore, carefully use a small screwdriver to remove the grommet. Use care not to damage the main control bore. NOTE: If transmission is being serviced for a contamination-related failure, use a new filter and seal. The filter may be reused if no excessive contamination is present. Replace fluid filter and seal as required. 9. Position the (B) pan magnet into the (A) transmission fluid pan. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4R70W > Page 5960 10. NOTE: The pan gasket is reusable, clean and inspect for damage; if not damaged, the gasket should be reused. Install the transmission fluid pan. 1 Position the transmission fluid pan gasket. 2 Position the transmission fluid pan. 11. Install the bolts. 12. Lower the vehicle. 13. Fill the transmission with fluid and check for proper operation. Disassembly and Assembly Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4R70W > Page 5961 Main Control Valve Body - Disassembled View (Part 1 Of 2) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4R70W > Page 5962 Part 2 Of 2 Disassembly 1. Remove the Torque Converter Clutch Solenoid (TCC solenoid) and the shift solenoid. 1 Remove the bolt. 2 Remove the shift solenoid. 3 Remove the torque converter clutch solenoid. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4R70W > Page 5963 2. Remove the three reinforcement plates. 1 Remove the ten main control valve body separator plate bolts. 2 Remove the three reinforcement plates. 3. Remove the separator plate and discard the gaskets. 4. NOTE: Note the location of the eight coasting booster valve shuttle balls for assembly. Remove the eight coasting booster valve shuttle balls. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4R70W > Page 5964 5. Remove the converter drain back valve and solenoid pressure supply screen. 6. Remove the main control valve body cover plate. 1 Remove the thirteen bolts. 2 Remove the valve body cover plate and gasket. Assembly 1. NOTE: Before beginning assembly, perform/inspect the following: When building up subassemblies and assembling the transmission, ALWAYS use new gaskets and seals. All fasteners must be tightened to the torque specification indicated. When building up subassemblies, each component part should be lubricated with clean transmission fluid. It is also good practice to lubricate the subassemblies as they are installed in the case. Needle bearings, thrust washers and seals should be lightly coated with petroleum jelly during subassembly buildup or transmission assembly. Many components and surfaces in the transmission are precision machined. Careful handling during disassembly, cleaning, inspection and Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4R70W > Page 5965 assembly can prevent unnecessary damage to machined surfaces. Install the valve body cover plate. 1 Position the valve body cover plate gasket and cover plate. 2 Install the two guide pin bolts. 3 Install the bolts. 2. Tighten the valve body cover plate bolts in the sequence shown. 3. Install the eight coasting booster valve shuttle balls. 4. Install the converter drain back valve and solenoid pressure supply screen. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4R70W > Page 5966 5. Install the separator plate and gaskets. 6. Install the three reinforcement plates. 1 Position the three reinforcement plates. 2 Install the bolts. 7. NOTE: Inspect the shift solenoid O-rings and TCC solenoid O-rings for damage. Install the shift solenoid. 1 Position the shift solenoid. 2 Position the TCC solenoid. 3 Install the bolt. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4R70W > Page 5967 Valve Body: Service and Repair 4R100 Removal and Installation Removal NOTE: If the transmission has been disassembled to replace worn or damaged parts, and the valves in the main control valve body stick repeatedly from foreign material, the torque converter must be removed and cleaned by using a mechanically agitated cleaner, such as the Torque Converter/Oil Cooler Cleaner. 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Disconnect the solenoid body electrical connector. 4. Remove the fluid pan gasket and filter. 5. Remove the accumulator body. 1 Remove the bolts. 2 Remove the nuts. 3 Remove the accumulator body. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4R70W > Page 5968 6. CAUTION: Prevent the front of the valve body separator plate from sagging and displacing the check balls. If the valve body separator plate is not being serviced: 1 Remove the bolt. 2 Install the bolt into any case-threaded bolt hole on the opposite end of the separator plate. 7. Remove the main control valve body assembly. 1 Remove the bolts. 2 Remove the nuts. 3 Remove the main control valve body. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4R70W > Page 5969 8. Remove the solenoid body assembly. 1 Remove the bolts. 2 Remove the nut. 3 Remove the solenoid body assembly. 9. Remove the solenoid screen assembly by rotating and pulling. 10. CAUTION: The steel Electronic Pressure Control (EPC) check ball is spring-loaded under the valve body separator plate. NOTE: If the valve body separator plates are not to be serviced, proceed to installation procedure. Remove the valve body separator plate reinforcement. 1 Remove the bolts. 2 Remove the separator plate reinforcement. 11. Lower and remove the valve body separator plate and gaskets. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4R70W > Page 5970 - The rubber check balls and the steel EPC check ball and spring assembly will fall out and may become lost or stick to the worm trail of the case. - Remove and discard separator plate gaskets. Installation CAUTION: Using the incorrect gaskets can cause damage to the transmission. 1. NOTE: Refer to parts catalog for proper gasket usage. NOTE: If the valve body separator plate was not removed, proceed to Step 6. NOTE: Apply a light film of petroleum jelly to the valve body separator plate prior to assembling the new gaskets. Assemble the new gaskets to the valve body separator plate. 1 Main control to case gasket. 2 Valve body separator plate. 3 Main control to separator plate gasket. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4R70W > Page 5971 Part 2 Of 2 2. NOTE: Apply a small amount of petroleum jelly to each check ball prior to positioning them on the valve body separator plate. Install eight rubber and one steel EPC check balls. 3. NOTE: Apply petroleum jelly to the EPC check ball spring prior to installing it into the case. Install the EPC check ball spring. 4. Position the valve body separator plate and the gaskets to the case carefully to retain the check balls. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4R70W > Page 5972 5. NOTE: The word "UP" stamped on the separator plate reinforcement, must be visible when installed. Install the separator plate reinforcement plate. 1 Position the separator plate reinforcement plate. 2 Install the bolts. 6. Install the solenoid screen assembly by pushing it in and rotating it to lock. 7. NOTE: Prior to installing the solenoid body assembly, coat the case connector bore with Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19331-A or equivalent meeting Ford specification ESE-M1C171-A. Install the solenoid body assembly. 1 Install the solenoid body assembly. 2 Install the nut. 3 Install the bolts and nut finger-tight. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4R70W > Page 5973 8. Install the main control valve body. 1 Install the main control valve body. 2 Aligning the manual shift valve with the manual valve detent lever. 3 Install the nuts finger-tight. 4 Install the bolts finger-tight. 9. If previously installed, remove, then reinstall the bolt into the separator plate reinforcing plate. 1 Remove the bolt. 2 Install the bolt. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4R70W > Page 5974 10. Install the accumulator body. 1 Install the accumulator body. 2 Install the nuts finger-tight. 3 Install the bolts finger-tight. 11. Tighten all the accumulator body, main control valve body, and solenoid body nuts and bolts. Tighten the bolts working from the center to the outside. 12. Install the fluid pan gasket and filter. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4R70W > Page 5975 13. Connect the solenoid body electrical connector. 14. Lower the vehicle. 15. Connect the battery ground cable. Disassembly and Assembly Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4R70W > Page 5976 Part 1 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4R70W > Page 5977 2 Of 3 Part 3 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4R70W > Page 5978 Disassembly NOTE: If main control is being replaced, refer to the parts catalog for correct parts. The main control is model-dependent. 1. Remove the lower control valve body. 1 Remove the bolts. 2 Remove the lower control valve body. 3 Remove the control valve body separator plate. 2. CAUTION: Note the location of the check balls prior to removal. If the check balls are not installed in their proper location shift problems will occur. Remove the check balls. 1 Remove two small check balls. 2 Remove two large check balls. 3. Remove the control valves and springs from the lower main control valve body. Inspect the valves for nicks and burrs. If the valves are damaged Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4R70W > Page 5979 the main control valve body will need to be replaced. 4. Remove the control valves and springs from the upper main control valve body. Inspect the valves for nicks and burrs. If the valves are damaged the main control valve body will need to be replaced. 5. Inspect all valves, valve sleeves, valve bores for scores, nick or burrs. Check all fluid passages for obstructions. Inspect all mating surfaces for burrs and scores. 6. Inspect all springs for distortion. Check all valves and plungers for free movement in their respective bores. All the components when dry must fall from their own weight in their respective bores. 7. Roll the valves on a flat surface to check for bent or out-of-round condition. Assembly 1. Install the control valves and springs from the lower main control valve body. 2. Install the control valves and springs from the upper main control valve body. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > 4R70W > Page 5980 3. Install the check ball 4. Install the lower control valve body using aligning pins. 1 Install aligning pins. 2 Install the control valve body separator plate. 3 Install the lower control valve body. 4 Install the bolts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Page 5981 Special Tool Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 99-19-7 > Sep > 99 > A/T 4R70W TCIL/MIL ON/Trouble Codes Stored Wiring Harness: Customer Interest A/T - 4R70W TCIL/MIL ON/Trouble Codes Stored Article No. 99-19-7 09/20/99 ^ LAMP - INTERMITTENT MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATION DIAGNOSTIC TROUBLE CODES (DTCS) P0741, P0750, P0755, AND P1746 MAY BE STORED IN MEMORY - VEHICLES BUILT FROM 8/1/1998 THROUGH 5/1/1999 WITH 4R70W TRANSMISSION ^ LAMP - INTERMITTENT TRANSMISSION CONTROL INDICATOR LAMP (TCIL) ILLUMINATION - DIAGNOSTIC TROUBLE CODES (DTCS) P0741, P0750, P0755, AND P1746 MAY BE STORED IN MEMORY - VEHICLES BUILT FROM 8/1/1998 THROUGH 5/1/1999 WITH 4R70W TRANSMISSION ^ TRANSMISSION - 4R7OW - INTERMITTENT TRANSMISSION CONTROL INDICATOR LAMP (TCIL) ILLUMINATION - DIAGNOSTIC TROUBLE CODES (DTCS) P0741, P0750, P0755, AND P1746 MAY BE STORED IN MEMORY - VEHICLES BUILT FROM 8/1/1998 THROUGH 5/1/1999 FORD: 1999 CROWN VICTORIA, MUSTANG, ECONOLINE, EXPEDITION, EXPLORER, F-150, F-250 LD LINCOLN: 1999 TOWN CAR MERCURY: 1999 GRAND MARQUIS, MOUNTAINEER This TSB article is being republished in its entirety to include additional vehicles and to correct the Service Procedure. ISSUE Intermittent Transmission Control Indicator Lamp (TCIL) or Malfunction Indicator Lamp (MIL) illumination may occur on some vehicles. The following Diagnostic Trouble Codes (DTCs) may be stored in memory: P0741, P0750, P0755, and P1746. This may be caused by the solenoid interconnect molded lead frame not being fully seated or the bulkhead interconnect clips not being fully seated between the solenoid interconnect molded lead frame and bulkhead interconnect. ACTION Verify the solenoid interconnect molded lead frame (-7G276-) is fully seated. If no concern is found, then inspect the bulkhead interconnect terminals for spread and/or not fully recessed. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal diagnosis for DTCs retrieved as outlined in the appropriate 1999 Workshop Manual. If root cause is not determined, continue with this TSB. 2. Remove the transmission oil pan per the appropriate model Workshop Manual, Section 307-01. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 99-19-7 > Sep > 99 > A/T 4R70W TCIL/MIL ON/Trouble Codes Stored > Page 5990 3. Verify that the solenoid interconnect molded lead frame is fully seated on all the solenoid connectors (Figure 1). If the solenoid interconnect molded lead frame is fully seated, then gently remove the solenoid interconnect molded lead frame, valve body, and bulkhead interconnect (-7G276-) per the appropriate model Workshop Manual, Section 307-01. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 99-19-7 > Sep > 99 > A/T 4R70W TCIL/MIL ON/Trouble Codes Stored > Page 5991 4. With the bulkhead interconnect removed, push down on the terminal cover and check to see if any of the terminals are slightly protruding above the plastic cover (Figure 2). Gently pry off the terminal cover using a small screwdriver (Figure 3). With the terminal cover off, inspect the bulkhead interconnect for spreading terminals (Figure 4). If the bulkhead interconnect terminals are spread or slightly protruding above the plastic cover, replace with a new Bulkhead Interconnect (F8AZ-7G276-AA). 5. Reassemble. PART NUMBER F8AZ-7G276-AA Bulkhead Interconnect F8AZ-7G276-BA Solenoid Interconnect OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-18-6 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest for Wiring Harness: > 99-19-7 > Sep > 99 > A/T 4R70W TCIL/MIL ON/Trouble Codes Stored > Page 5992 OPERATION DESCRIPTION TIME 991907A Perform Inspection And 1.3 Hrs. Replace Bulkhead Interconnect DEALER CODING CONDITION BASIC PART NO. CODE 7G276 42 OASIS CODES: 206000, 501000, 502000, 504000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 99-19-7 > Sep > 99 > A/T - 4R70W TCIL/MIL ON/Trouble Codes Stored Wiring Harness: All Technical Service Bulletins A/T - 4R70W TCIL/MIL ON/Trouble Codes Stored Article No. 99-19-7 09/20/99 ^ LAMP - INTERMITTENT MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATION DIAGNOSTIC TROUBLE CODES (DTCS) P0741, P0750, P0755, AND P1746 MAY BE STORED IN MEMORY - VEHICLES BUILT FROM 8/1/1998 THROUGH 5/1/1999 WITH 4R70W TRANSMISSION ^ LAMP - INTERMITTENT TRANSMISSION CONTROL INDICATOR LAMP (TCIL) ILLUMINATION - DIAGNOSTIC TROUBLE CODES (DTCS) P0741, P0750, P0755, AND P1746 MAY BE STORED IN MEMORY - VEHICLES BUILT FROM 8/1/1998 THROUGH 5/1/1999 WITH 4R70W TRANSMISSION ^ TRANSMISSION - 4R7OW - INTERMITTENT TRANSMISSION CONTROL INDICATOR LAMP (TCIL) ILLUMINATION - DIAGNOSTIC TROUBLE CODES (DTCS) P0741, P0750, P0755, AND P1746 MAY BE STORED IN MEMORY - VEHICLES BUILT FROM 8/1/1998 THROUGH 5/1/1999 FORD: 1999 CROWN VICTORIA, MUSTANG, ECONOLINE, EXPEDITION, EXPLORER, F-150, F-250 LD LINCOLN: 1999 TOWN CAR MERCURY: 1999 GRAND MARQUIS, MOUNTAINEER This TSB article is being republished in its entirety to include additional vehicles and to correct the Service Procedure. ISSUE Intermittent Transmission Control Indicator Lamp (TCIL) or Malfunction Indicator Lamp (MIL) illumination may occur on some vehicles. The following Diagnostic Trouble Codes (DTCs) may be stored in memory: P0741, P0750, P0755, and P1746. This may be caused by the solenoid interconnect molded lead frame not being fully seated or the bulkhead interconnect clips not being fully seated between the solenoid interconnect molded lead frame and bulkhead interconnect. ACTION Verify the solenoid interconnect molded lead frame (-7G276-) is fully seated. If no concern is found, then inspect the bulkhead interconnect terminals for spread and/or not fully recessed. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Perform normal diagnosis for DTCs retrieved as outlined in the appropriate 1999 Workshop Manual. If root cause is not determined, continue with this TSB. 2. Remove the transmission oil pan per the appropriate model Workshop Manual, Section 307-01. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 99-19-7 > Sep > 99 > A/T - 4R70W TCIL/MIL ON/Trouble Codes Stored > Page 5998 3. Verify that the solenoid interconnect molded lead frame is fully seated on all the solenoid connectors (Figure 1). If the solenoid interconnect molded lead frame is fully seated, then gently remove the solenoid interconnect molded lead frame, valve body, and bulkhead interconnect (-7G276-) per the appropriate model Workshop Manual, Section 307-01. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 99-19-7 > Sep > 99 > A/T - 4R70W TCIL/MIL ON/Trouble Codes Stored > Page 5999 4. With the bulkhead interconnect removed, push down on the terminal cover and check to see if any of the terminals are slightly protruding above the plastic cover (Figure 2). Gently pry off the terminal cover using a small screwdriver (Figure 3). With the terminal cover off, inspect the bulkhead interconnect for spreading terminals (Figure 4). If the bulkhead interconnect terminals are spread or slightly protruding above the plastic cover, replace with a new Bulkhead Interconnect (F8AZ-7G276-AA). 5. Reassemble. PART NUMBER F8AZ-7G276-AA Bulkhead Interconnect F8AZ-7G276-BA Solenoid Interconnect OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-18-6 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 99-19-7 > Sep > 99 > A/T - 4R70W TCIL/MIL ON/Trouble Codes Stored > Page 6000 OPERATION DESCRIPTION TIME 991907A Perform Inspection And 1.3 Hrs. Replace Bulkhead Interconnect DEALER CODING CONDITION BASIC PART NO. CODE 7G276 42 OASIS CODES: 206000, 501000, 502000, 504000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Specifications Clutch Disc: Specifications O.S. Diameter (approx) 290 mm I.S. Diameter (approx) 185 mm Facing Area 783 Sq. cm Compressed Thickness 9.0 mm Lining Material Woven non-asbestos No. Torsion Springs 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Specifications > Page 6005 Clutch Disc: Testing and Inspection Special Tools CLUTCH DISC CHECK 1. Remove clutch assembly. 2. NOTE: Use emery cloth to remove minor imperfections in the clutch disc lining surface. Inspect clutch disc for: Oil or grease saturation. - Worn or loose rivets at the hub. - Broken springs. - Wear or rust on splines. Replace the clutch disc if any of these conditions are present. 3. Use a slide caliper to measure the depth to the rivet heads. - Replace the clutch disc if not within specification. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Specifications > Page 6006 4. Use (A) Dial Indicator/Magnetic Base to inspect the (B) clutch disc runout. Replace the clutch disc if not within specification. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Specifications > Page 6007 Clutch Disc: Service and Repair Special Tools Removal 1. Remove the transmission. 2. If the parts are to be reused, mark the clutch pressure plate and the flywheel. 3. Remove the clutch pressure and clutch disc. 1 Remove the bolts. 2 Remove the clutch pressure plate and the clutch disc. Installation 1. NOTE: The self-adjusting clutch pressure plate should always be adjusted before installation. Compress the clutch diaphragm fingers. 1 Place (A) the flywheel and (B) the pressure plate in a press. 2 Use a (C) suitable adapter and press the (D) clutch diaphragm fingers until the adjusting ring moves freely. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Specifications > Page 6008 2. Adjust the clutch pressure plate. - Rotate (A) adjusting ring counterclockwise until the (B) tension springs are compressed. - Hold (A) adjusting ring while releasing the pressure on the clutch fingers. 3. Position the (A) clutch disc on the (B) flywheel. - Use (C) Clutch Aligner to align the clutch disc. 4. NOTE: If reusing the clutch pressure plate and flywheel, use marks made during removal. Position the clutch pressure on three dowels. 1 Align the clutch pressure plate. Install the clutch pressure plate bolts. 2 Remove the Clutch Aligner. 5. Install the transmission. 6. Operate the vehicle to check clutch operation. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Specifications > Page 6009 Clutch Disc: Tools and Equipment Special Tools Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Specifications Clutch Fluid: Specifications - Use Ford High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Service and Repair > Bleeding - Clutch Master Cylinder Clutch Fluid: Service and Repair Bleeding - Clutch Master Cylinder 1. Install clutch master cylinder in a vise. NOTE: When bleeding a dry replacement clutch master cylinder, remove clutch master cylinder-to-clutch slave cylinder tubing from vehicle and install to new master cylinder. 2. Fill master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AA or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 3. Insert clutch slave cylinder end of tube in a waste container to prevent fluid from leaking. 4. Push the master cylinder push rod all the way in. While holding the push rod in, plug the end of the tube to prevent air from entering the tube and master cylinder. Perform this step several times until all air has been bled from the clutch master cylinder. NOTE: Be sure to keep clutch master cylinder reservoir full during this operation to prevent additional air from entering the master cylinder. 5. When all air is expelled from the clutch master cylinder (no bubbles come out of the tube), install the clutch master cylinder and tubing to the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid > Component Information > Service and Repair > Bleeding - Clutch Master Cylinder > Page 6016 Clutch Fluid: Service and Repair Bleeding - Clutch Slave Cylinder Clutch Hydraulic System Bleeding, Concentric Cylinder Clutch Slave 1. If bleeding a dry replacement clutch master cylinder, refer to Bench Bleed Procedure, Clutch Master Cylinder. See: Clutch Master Cylinder/Service and Repair 2. Disconnect the coupling at the transmission with Coupling Disconnect Tool T88T-70522-A or equivalent by sliding the white plastic sleeve toward the clutch slave cylinder while applying a slight tug on the clutch tube. CAUTION: Make sure hydraulic tube connection is free of contamination prior to disconnecting it. 3. Remove cap and diaphragm and fill reservoir to the step with High Performance DOT 3 Brake Fluid C6AZ-19542-AA or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. CAUTION: - Clean dirt and grease from around the reservoir cap. - Brake fluid must be certified to DOT 3 specification. 4. Apply 10-15 pounds of pressure to clutch pedal. 5. Using a small screwdriver, press the internal mechanism of the male coupling to open the valve. While continuing to hold the valve open, slowly depress the clutch pedal to the floor and hold. 6. Remove the screwdriver from the coupling, closing the valve. 7. Release the clutch pedal. 8. Refill reservoir to level at step. CAUTION: The reservoir must be kept full at all times to make sure there will be no additional introduction of air into the system. 9. Repeat Steps 4 through 7. 10. Close reservoir. Reconnect the coupling to the clutch slave cylinder. Check that the connection is secure by applying a slight tug to the clutch tube. 11. Stroke the clutch pedal as rapidly as possible for five to ten strokes. 12. Wait one to three minutes. 13. Repeat Steps 11 and 12 three more times. 14. Loosen bleed screw (located in the slave cylinder body next to the inlet connection). 15. Depress and hold clutch pedal while tightening bleed screw 3-5 Nm (27-44 inch lbs.). 16. Refill the reservoir to level at step. 17. The hydraulic system should now be fully bled and should properly release the clutch. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair Clutch Master Cylinder: Service and Repair Removal NOTE: When replacing clutch master cylinder, remove tubing from vehicle for bench bleeding procedure See: Clutch Fluid/Service and Repair. 1. Disconnect the clutch master cylinder push rod from the clutch and brake pedal pivot shaft lever. 2. Disconnect the Clutch Pedal Position Switch (CPP). 3. Remove the pushpins. 4. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking, or towing an air suspension vehicle. This can be accomplished by turning off the R.H. kick panel area. Failure to inflation of deflation of the air springs which may result in shifting of the vehicle during these operations. Raise and support the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Page 6020 5. Disconnect the clutch hydraulic line from the slave cylinder. 6. Lower the vehicle. 7. Remove the clutch master cylinder reservoir and clutch master cylinder. - Rotate the clutch master cylinder 45 degrees clockwise. 8. CAUTION: Clean all rubber clutch master cylinder parts with Ford High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A. Clean all clutch master cylinder components. 9. Inspect the clutch master cylinder for: - weak spring, - damage to any reservoir components. - damaged cups. - scored piston. Installation 1. Lightly clamp clutch master cylinder reservoir in a vise. 2. Fill clutch master cylinder reservoir to full line. - Use Ford High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A. 3. Place clutch slave cylinder end of tube in a waste container. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Page 6021 4. NOTE: Make sure the clutch master cylinder reservoir is full during bleeding procedure to prevent air from entering the clutch master cylinder. NOTE: Bleed the clutch master cylinder until a solid stream of brake fluid exits at the quick connect coupling end of tube. Open the internal mechanism of the mate quick connect coupling and fully depress and hold the clutch master cylinder push rod. 5. Release the (A) internal mechanism of the quick end connector and release the (B) clutch master cylinder push rod. 6. Install the clutch master cylinder. - Rotate the clutch master cylinder 45 degrees counterclockwise. 7. Install the pushpins. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder > Component Information > Service and Repair > Page 6022 8. Connect the clutch pedal position switch. 9. Connect the clutch master cylinder push rod and retainer bushing. 10. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking, or towing an air suspension vehicle. This can be accomplished by turning off the R.H. kick panel area. Failure to inflation of deflation of the air springs which may result in shifting of the vehicle during these operations. Raise and support the vehicle. 11. Connect the clutch hydraulic line to the transmission. 12. Lower the vehicle. 13. Turn on the air suspension switch, if equipped. 14. Bleed the clutch hydraulic system See: Clutch Fluid/Service and Repair. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Specifications Clutch Slave Cylinder: Specifications Clutch Slave Cylinder Bolts 19-26 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Specifications > Page 6026 Clutch Slave Cylinder: Service and Repair Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking, or towing an air suspension vehicle. This can be accomplished by turning off the R.H. kick panel area. Failure to inflation of deflation of the air springs which may result in shifting of the vehicle during these operations. Raise the vehicle on a hoist. 2. Remove the hydraulic line from the slave cylinder. 3. Remove the slave cylinder. Installation 1. Install the slave cylinder. 2. Install the hydraulic line. 3. Install the transmission. 4. Lower the vehicle. 5. Turn on the air suspension system, if equipped. 6. Bleed the hydraulic system See: Clutch Fluid/Service and Repair. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Service and Repair Hydraulic Hose: Service and Repair Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking, or towing an air suspension vehicle. This can be accomplished by turning off the R.H. kick panel area. Failure to inflation of deflation of the air springs which may result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Disconnect the line from the plastic clip at the floor flange. 3. Uncouple the lower end of the line from the clutch slave cylinder. 4. Lower the vehicle. 5. Remove the clutch master cylinder and line assembly. 6. Remove and discard the roll pin holding the line to the clutch master cylinder. 7. NOTE: Check that the O-ring is still in the outlet port of the clutch master cylinder. If not, replace it. Disconnect the line from the clutch master cylinder by applying a slight tug on the line. Installation 1. Insert the new line into the clutch master cylinder outlet port. 2. Install the clutch master cylinder tube. 1 Position the line and install the roll pin. 2 Tug on the clutch master cylinder tube. 3. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking, or towing an air suspension vehicle. This can be accomplished by turning off the R.H. kick panel area. Failure to inflation of deflation of the air springs which may result in shifting of the vehicle during these operations. Raise and support the vehicle. 4. Bleed the system See: Clutch Fluid/Service and Repair. 5. NOTE: Check that the O-ring is in place on the line. Check the clutch slave cylinder port to be sure there is no O-ring. Insert the male coupling end into the female coupling of the clutch slave cylinder. Check that the connection is secure by applying a slight tug to the line. 6. Connect the line to the plastic clip on the floor flange. 7. Lower the vehicle. 8. Turn on the air suspension switch, if equipped. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch > Component Information > Service and Repair > Page 6030 Hydraulic Hose: Tools and Equipment Clutch Line Fork AST tool# 8008 Used for the R and R of the hydraulic clutch line from the internally mounted slave cylinder. This tool is applicable to the following Ford vehicles with manual transmissions: 1989 and later Ford Aerostar, Bronco II, Explorer, F150 and Ranger. - For R and R of Hydraulic Clutch Lines - Applicable to Ford Models with Manual Transmissions - Steel Construction - Black-Oxide Finish Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Specifications Clutch Pedal Assembly: Specifications Clutch Pedal Type Suspended Clutch Pedal Travel 153-177 mm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Specifications > Page 6034 Clutch Pedal Assembly: Service and Repair Removal 1. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface wash it immediately with water. Disconnect the clutch master cylinder push rod. 2. Remove the retainer ring and discard. 3. Remove the clutch pedal from the pedal support bracket. Installation 1. Install the clutch pedal assembly. - Install the clutch pedal bushings and washers. - Install the clutch pedal shaft threads, the clutch/brake pedal support and brake pedal. 2. Install the retainer ring. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Specifications > Page 6035 3. Install the clutch master cylinder push rod to pedal pin. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Locations > Page 6039 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Locations > Page 6040 Clutch Switch: Description and Operation The Clutch Pedal Position (CPP) switch is controlled by the clutch pedal. Depressing the clutch pedal manually closes the CPP switch and allows engine cranking. The CPP switch will also deactivate the speed control system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information > Locations > Page 6041 Clutch Switch: Service and Repair REMOVAL 1. Disconnect the Clutch Pedal Position switch (CPP) electrical connector. 2. Release the clutch pedal position switch from the orientation clip. 3. Remove the plastic retainer. 1 Push the lock tabs together. 2 Slide the plastic retainer off the clutch pedal position switch. 4. Remove the clutch pedal position switch. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Testing and Inspection Pilot Bearing: Testing and Inspection 1. Inspect the transmission input shaft pilot bearing for: - Misalignment and looseness in the crankshaft. - Needle rollers (A) for scoring, worn or broken rollers, inadequate grease or discoloration. - Seal leakage (B). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Testing and Inspection > Page 6045 Pilot Bearing: Service and Repair Special Tools Removal 1. NOTE: If damaged, install a new transmission input shaft pilot bearing. Using (B) Impact Slide Hammer and (C) Puller and remove the (A) transmission input shaft pilot bearing. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Testing and Inspection > Page 6046 1. NOTE: The transmission input shaft pilot bearing can only be installed with the seal facing the transmission. The transmission input shaft pilot bearing is pregreased and does not require additional lubrication. A new transmission input shaft pilot bearing must be installed whenever it is removed. Using the (B) Pilot Bearing Replacer, install the (A) transmission input shaft pilot bearing. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Testing and Inspection > Page 6047 Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications Pressure Plate: Specifications Clutch Pressure Plate Bolts 35-46 ft.lb Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Specifications > Page 6051 Pressure Plate: Adjustments 1. NOTE: Self adjusting clutch pressure plate should always be adjusted before installation. Compress the clutch diaphragm fingers. 1 Place (A) flywheel and (B) clutch pressure plate in a press. 2 Use a (C) suitable adapter and press the (D) clutch diaphragm fingers until the adjusting ring moves freely. 2. Adjust the clutch pressure plate. - Rotate (A) adjusting ring counterclockwise until the (B) tension springs are compressed, - Hold (A) adjusting ring while releasing the pressure on the clutch fingers. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Side Gears > Component Information > Technical Service Bulletins > Customer Interest: > 99-14-3 > Jul > 99 > Front Differential Moaning Noise In 2WD Mode Carrier Side Gears: Customer Interest Front Differential - Moaning Noise In 2WD Mode Article No. 99-14-3 07/12/99 ^ NOISE - "MOANING" FROM FRONT DIFFERENTIAL WHILE IN 2-WHEEL DRIVE - VEHICLES BUILT THROUGH 4/15/1999 ^ AXLE - "MOANING" NOISE FROM FRONT DIFFERENTIAL WHILE IN 2-WHEEL DRIVE VEHICLES BUILT THROUGH 4/15/1999 FORD: 1997-1999 EXPEDITION, F-150, F-250 LD LINCOLN: 1998-1999 NAVIGATOR ISSUE Some 4X4 vehicles built with center disconnect front axles may exhibit a "moaning" noise from the front differential while operating in 4X2 mode. The noise goes away when operating in 4X4 mode. This may be caused by the front differential side gears. ACTION Replace the front differential side gears with revised gears and replace the front differential pinion gears with revised gears. Refer to the following text for details. For vehicles that exhibit a front differential moan in 4X2 mode that goes away in 4X4 mode, replace both front axle side gears and both front axle pinion gears. Replace any worn or damaged pinion thrust washers and side gear washers. Refer to Section 205-03 of the appropriate model/year Workshop Manual for removal and installation procedures. PART NUMBER PART NAME XL3Z-4236-M Side Gears (2 Per Box) XL3Z-4215-M Pinion Gears (2 Per Box) DOAZ-4230-B Pinion Thrust washer C90Z-4228-B Side Gear washer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991403A Replace Axle Side Gears 1.4 Hrs. And Pinion Gears DEALER CODING CONDITION BASIC PART NO. CODE 4235 42 OASIS CODES: 509000, 597997, 702100 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Side Gears > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-14-3 > Jul > 99 > Front Differential - Moaning Noise In 2WD Mode Carrier Side Gears: All Technical Service Bulletins Front Differential - Moaning Noise In 2WD Mode Article No. 99-14-3 07/12/99 ^ NOISE - "MOANING" FROM FRONT DIFFERENTIAL WHILE IN 2-WHEEL DRIVE - VEHICLES BUILT THROUGH 4/15/1999 ^ AXLE - "MOANING" NOISE FROM FRONT DIFFERENTIAL WHILE IN 2-WHEEL DRIVE VEHICLES BUILT THROUGH 4/15/1999 FORD: 1997-1999 EXPEDITION, F-150, F-250 LD LINCOLN: 1998-1999 NAVIGATOR ISSUE Some 4X4 vehicles built with center disconnect front axles may exhibit a "moaning" noise from the front differential while operating in 4X2 mode. The noise goes away when operating in 4X4 mode. This may be caused by the front differential side gears. ACTION Replace the front differential side gears with revised gears and replace the front differential pinion gears with revised gears. Refer to the following text for details. For vehicles that exhibit a front differential moan in 4X2 mode that goes away in 4X4 mode, replace both front axle side gears and both front axle pinion gears. Replace any worn or damaged pinion thrust washers and side gear washers. Refer to Section 205-03 of the appropriate model/year Workshop Manual for removal and installation procedures. PART NUMBER PART NAME XL3Z-4236-M Side Gears (2 Per Box) XL3Z-4215-M Pinion Gears (2 Per Box) DOAZ-4230-B Pinion Thrust washer C90Z-4228-B Side Gear washer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991403A Replace Axle Side Gears 1.4 Hrs. And Pinion Gears DEALER CODING CONDITION BASIC PART NO. CODE 4235 42 OASIS CODES: 509000, 597997, 702100 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Side Gears > Component Information > Technical Service Bulletins > All Other Service Bulletins for Carrier Side Gears: > 02-10-8 > May > 02 > Fuel System - Whistling Noise Auxiliary Air Valve (Idle Speed): All Technical Service Bulletins Fuel System - Whistling Noise Article No. 02-10-8 05/27/02 ^ DRIVEABILITY - 5.4L 2V - IDLE-AIR BYPASS FLOW INDUCED WHISTLE ^ ENGINE - 5.4L 2V - IDLE-AIR BYPASS FLOW INDUCED WHISTLE ^ NOISE - IDLE-AIR BYPASS FLOW INDUCED WHISTLE - VEHICLES EQUIPPED WITH 5.4L 2V ENGINE ONLY FORD: 1999-2002 E SERIES, EXPEDITION, F-150, SUPER DUTY F SERIES ISSUE Some vehicles equipped with the 5.4L 2V engine may exhibit a "whistling" noise from the formed nylon tube in the idle-air bypass flow circuit. This may be caused by air flow passing through the sharp bend radius of the original tube assembly. ACTION Remove and replace formed nylon tube with the Nipple And Hose Assembly 2L1Z-9W548-AA. This action will correct the sharp bend in the tube. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the formed tube as shown (Figure 1). 2. Replace with Nipple And Hose Assembly with part 2L1Z-9W548-AA. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Side Gears > Component Information > Technical Service Bulletins > All Other Service Bulletins for Carrier Side Gears: > 02-10-8 > May > 02 > Fuel System - Whistling Noise > Page 6072 3. Connect nipple to the air-inlet zip tube and the free end connects to resonator as shown (Figure 2). 4. Ensure that there are no kinks in the rubber hose which could restrict air flow. LABOR OPERATION CLAIMING CHART PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9H308 V3 OASIS CODES: 497000, 702000, 702100 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Side Gears > Component Information > Technical Service Bulletins > All Other Service Bulletins for Carrier Side Gears: > 02-10-8 > May > 02 > Fuel System - Whistling Noise > Page 6078 3. Connect nipple to the air-inlet zip tube and the free end connects to resonator as shown (Figure 2). 4. Ensure that there are no kinks in the rubber hose which could restrict air flow. LABOR OPERATION CLAIMING CHART PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 9H308 V3 OASIS CODES: 497000, 702000, 702100 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Testing and Inspection Differential Case: Testing and Inspection Special Tools Special Tools FRONT RUNOUT CHECK 1. Remove the front drive axle assembly. 2. Remove the differential housing cover. 1 Remove the drain plug. 2 Drain the lubricant. 3 Remove the bolts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Testing and Inspection > Page 6082 4 Remove the differential housing cover. 3. CAUTION: The fixture mounting bolts must have the minimum specified thread engagement in the carrier. Install the special tool. 4. Install the special tool. 5. Rotate the differential and check the ring gear back face runout. - If the ring gear back face runout exceeds the specification, the cause may be a warped ring gear, differential case damage or loss of differential bearing preload. To determine the cause, proceed as follows: 6. Remove the pinion gear. 7. Remove the Differential Carrier Spreader. 8. Install the differential assembly with the differential bearing cups in the carrier housing. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Testing and Inspection > Page 6083 9. Install the differential bearing shim on the left side. 10. Install the LH differential bearing cap. 1 Position the bearing cap. 2 Install the bolts finger-tight. 11. Install progressively larger differential bearing shims on the RH side until the largest differential bearing shim can be assembled with a slight drag feel. 12. Install the RH bearing cap, and tighten the four bolts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Testing and Inspection > Page 6084 13. Rotate the assembly to make sure it turns freely. 14. Install the special tool. 15. Rotate the differential and check the ring gear back face runout. - If the runout is within the specifications, insufficient bearing preload caused the original out-of-specification runout. If the runout exceeds the specification, proceed as follows: 16. Remove the bearing caps. 1 Remove the bolts. 2 Remove the bearing caps. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Testing and Inspection > Page 6085 17. Remove the differential case from the housing. 18. Remove the ring gear. - Remove the ten bolts. - Use a drift punch to separate the ring gear from the differential case. 19. Install the differential case in the housing. 1 Position the differential case. 2 Install the bearing caps. 3 Install the bolts. 4 Rotate the differential case to make sure the bearings have seated correctly. 20. Install the special tool. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Testing and Inspection > Page 6086 21. Rotate the differential case and check the differential case runout. - If the runout does not exceed the specification, install a new ring gear and pinion. If runout exceeds the specification, the ring gear is true and the condition is due to differential case/differential bearing damage. Inspect the differential bearings and the differential case. Always install new differential bearings when installing a new differential case. 22. Remove the bearing caps. 1 Remove the bolts. 2 Remove the bearing caps. 23. Remove the differential case from the housing. 24. If necessary, using the special tools, remove the differential bearings. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Testing and Inspection > Page 6087 25. CAUTION: Press against the differential bearing inner cone only. Install the new differential bearings. 1 Position the appropriate differential bearing (RH or LH). 2 Using a suitable press and the special tool, install the differential bearing. Repeat the procedure for the other differential bearing. 26. Install the differential case in the housing. 1 Position the differential case. 2 Install the bearing caps. 3 Install the bearing cap bolts. 4 Rotate the differential case to make sure the bearings have seated correctly. 27. Install the special tool. 28. Recheck the runout with the new differential bearings. If the runout does not exceed the specification, use the new differential bearings for assembly. If the runout is still excessive, install a new differential case. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Testing and Inspection > Page 6088 29. Remove the bolts. 30. Remove the differential case from the housing. 1 Remove the bearing caps. 2 Remove the differential case. 31. Install the pinion gear, the ring gear, and the differential assembly. 32. Install the front drive axle assembly. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation Differential Case: Service and Repair Removal & Installation Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. With the transmission in Neutral, raise and support the vehicle. 2. Index-mark the front driveshaft to the axle universal joint flange. 3. CAUTION: Do not allow the driveshaft to hang unsupported. Disconnect and support the front driveshaft. 1 Remove the four bolts. 2 Carefully disconnect and support the front driveshaft. 4. CAUTION: Do not allow the halfshaft to hang unsupported. Remove the six bolts and disconnect the front drive halfshaft. Repeat Step 4 for the opposite side. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6091 5. Disconnect the vacuum lines and the front axle vent tube. 6. Use a high-lift Jack to support the axle assembly. 7. Remove the front differential support. 1 Remove the nut and bolt. 2 Remove the nuts and bolts. 3 Remove the front differential support. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6092 8. Remove the nut and bolt. 9. Remove the nut and bolt. 10. Carefully lower the front drive axle assembly. Installation 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6093 Differential Case: Service and Repair Disassembly Part 1 Of 5 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6094 Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6095 Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6096 Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6097 Special Tools Special Tools 1. Remove the front drive axle assembly, please refer to Transmission and Drivetrain/Differential Assembly/Service and Repair/Procedures/Front/ See: Removal & Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6098 2. Remove the differential housing cover. 1 Remove the drain plug. 2 Drain the fluid. 3 Remove the bolts. 4 Remove the differential housing cover. 3. CAUTION: The fixture mounting bolts must have the minimum specified thread engagement in the carrier. Install the special tool. 4. Unseat the clutch shaft rod boot. 5. Remove the E-ring. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6099 6. Disconnect the front axle actuator motor assembly. 1 Fully extend the actuator motor shaft. 2 Plug the vacuum ports. 3 Pull outward on the front axle actuator motor assembly. 4 Push the front axle actuator motor assembly to disconnect the shift lever from the slot in the actuator motor shaft. 7. Remove the clutch shaft rod boot, and the front axle actuator motor assembly. 1 Remove the clutch shaft rod boot. 2 Remove the front axle actuator motor assembly. 8. Remove the axle housing tube, please refer to Transmission and Drivetrain/Differential Assembly/Service and Repair/Procedures/Front/ See: Axle Tube Disassembly and Assembly 9. Remove the thrust washer. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6100 10. Remove the axle cluster gear shaft. 11. CAUTION: Use a vise with soft jaws. Using the special tool, remove the pilot bearing assembly from the axle cluster gear shaft. 1 Position the axle cluster gear shaft in the vise. 2 Using the special tool, remove the pilot bearing assembly. 12. Lift the shift lever, and remove the coupler shift selector gear. 13. NOTE: There is enough clearance in the casting to remove the manual shaft retaining pin. If necessary, remove the shift lever and the clutch fork. 1 Drive the manual shaft retaining pin through the clutch fork. 2 Remove the shift lever and the clutch fork. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6101 14. Remove and discard the O-ring. 15. Remove the axle shaft. 1 Remove the snap ring. 2 Remove the axle shaft. 16. CAUTION: The housing spreader adapter bolts must have the minimum specified thread engagement in the carrier. Install the special tools. 17. Position the special tool on the spreader adapters. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6102 18. If necessary, adjust the special tool to provide clearance for the shift lever. 19. Install the special tools. Position the adapter tip in the spreader adapter hole. 20. CAUTION: Overspreading can damage the axle housing. Spread the axle housing to the specification. 1 Adjust the special tool to zero. 2 Tighten the housing spreader screw to spread the axle housing to the specification. 3 Remove the special tool. 21. CAUTION: Mark the differential bearing caps Top or Bottom and LH or RH appropriately before removing them. Always install the bearing caps in their original place and position. Mark and remove the differential bearing caps, 1 Remove the bolts. 2 Remove the differential bearing caps. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6103 22. CAUTION: Use wood blocks to avoid axle housing damage. Remove the differential assembly from the axle housing. 1 Position the wood blocks. 2 Position and push down on the two pry bars. 3 Remove the differential assembly. 4 Remove the special tool. 23. Index-mark the axle universal joint flange to the pinion stem. 24. Install the special tool, and loosen, but do not remove the pinion nut. 25. With the pinion nut still engaged by a few threads, use the special tool to separate the axle universal joint flange from the pinion gear. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6104 26. Using the special tool and a soft hammer, remove the pinion gear. 1 Install the special tool. 2 Hold the pinion gear inside the carrier housing. 3 Using a soft face hammer, remove the pinion gear from the carrier housing. 27. Discard the drive pinion collapsible spacer. 28. CAUTION: Do not damage the carrier housing while removing the pinion seal. Remove the pinion seal and slinger. Pry up on the seal flange. Install gripping pliers, and strike with a hammer to remove the seal. 29. Remove the outer pinion bearing. 30. Using the special tools, remove the inner pinion bearing cup. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6105 31. NOTE: The pinion bearing oil baffle aids in bearing lubrication. Normally, it is not necessary to remove the baffle. If necessary, remove the pinion bearing oil baffle. 32. Remove the outer pinion bearing cup by tapping alternately on each side to prevent the cup from cocking. 33. Using the special tool and a suitable press, remove the pinion bearing. 34. NOTE: A drive pinion bearing adjustment shim sits under the pinion bearing. Use a micrometer to measure the shim thickness. Record the measurement for comparison to the shim gauge reading taken prior to installing the pinion bearing. Remove and measure the drive pinion bearing adjustment shim. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6106 35. Remove the ten bolts and the ring gear. - Use a drift punch to separate the ring gear from the differential case. 36. Using the special tools, remove the differential bearings. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6107 Differential Case: Service and Repair Assembly Part 1 of 2 1. CAUTION: Do not omit the pinion bearing oil baffle; bearing failure can result. If removed, position the baffle on the special tool. 2. Using the special tool, install the baffle. 3. NOTE: Always install new pinion bearings when installing new pinion bearing cups. Lightly oil the new pinion bearing cups and pinion bearings with Motorcraft SAE75W90 4x4 Axle Lubricant XY-75W90-QL or equivalent meeting Ford specification WSP-M2C201-A. 4. Using the special tool, install the bearing cups. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6108 5. NOTE: You must use the pinion bearings assembled in this procedure step at final assembly. Assemble and position the special tools and the pinion bearings in the carrier housing. 1 Position the Screw. 2 Position the Aligning Adapter. 3 Position the pinion bearing. 4 Position the Gauge Disc. 5 Position the Gauge Block. 6 Position the pinion bearing. 7 Thread on the Handle. 6. NOTE: This step duplicates final pinion bearing preload. Tighten the special tool to the specification to simulate bearing preload. 7. NOTE: Offset the Gauge Block to obtain an accurate reading. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6109 Rotate the Gauge Block several half-turns to make sure the pinion bearings seat correctly, and position the Gauge Block. 8. Install the special tool. 1 Position the special tool. 2 Install the differential bearing caps. 3 Install the bolts. 9. NOTE: Use only flat, clean drive pinion bearing adjustment shims. NOTE: Selection of a shim that is too thick results in a deep tooth contact at final assembly of integral axle assemblies. Do not attempt to force the shim between the Gauge Block and the Gauge Tube. A slight drag indicates correct shim selection. Use a drive pinion bearing adjustment shim as a gauge for shim selection. Check the adjustment shim thickness between the Gauge Block and the Gauge Tube. - After determining the correct shim thickness, remove the special tools. 10. NOTE: You must use the same pinion bearings from the previous steps. Install the pinion bearing. Place the drive pinion bearing adjustment shim on the pinion gear. - Using a suitable press and the special tool, press the pinion bearing until it is firmly seated on the pinion gear. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6110 11. Place a new drive pinion collapsible spacer on the pinion stem. 12. Install the outer pinion bearing. 13. Install the slinger. 14. NOTE: Coat the lips of the pinion seal with Motorcraft SAE 75W90 4x4 Axle Lubricant XY-75W90-QL or equivalent meeting Ford specification WSP-M2C201-A. Place the pinion seal on the special tool. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6111 15. Place the special tool and seal in the pinion seal bore and drive the seal into place. 16. Lightly lubricate the pinion gear splines with Motorcraft SAE 75W90 4x4 Axle Lubricant XY-75W90-QL or equivalent meeting Ford specification WSP-M2C201-A. 17. Position the pinion gear. 18. CAUTION: Never install the axle universal joint flange with a hammer. NOTE: Disregard the scribe marks if installing a new flange. Align the index-marks and position the universal joint flange on the pinion shaft. 19. NOTE: Rotate the pinion gear occasionally to make sure the pinion bearings seat correctly. Using the special tool, install the axle universal joint flange. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6112 20. Apply a small amount of lubricant to the washer side of the new pinion nut, and install the nut. 21. CAUTION: Do not loosen the pinion nut to reduce preload under any circumstance. If it is necessary to reduce preload, install a new drive pinion collapsible spacer and pinion nut. Install the special tool, and tighten the pinion nut. Rotate the pinion gear occasionally to make sure the pinion bearings are seating correctly. Take frequent pinion bearing torque preload readings by rotating the pinion gear with an Nm (inch/pound) torque wrench. 22. CAUTION: Use extreme care not to damage the aluminum differential carrier housing while performing the following procedure steps. CAUTION: The special tools are marked LH and RH. Install them accordingly. Install the special tools. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6113 23. Install the differential case with the Master Bearings in the differential carrier. 24. NOTE: Repeat this step until you obtain a consistent reading. Measure the total end play. 1 Position the special tools. 2 Position the indicator tip on the machined surface and adjust it to measure full travel. 3 Push the differential case left and right (as far as possible). 4 Measure the total end play and record the reading on the Differential Bearing Shim Selection Procedure Worksheet, Line A, in this procedure. 25. Remove the special tools and the differential case. 26. Use a fine flat file to remove any burrs or nicks from the ring gear mounting surface. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6114 27. Install the ring gear. 1 Position three bolts to align the holes in the ring gear and the differential case. 2 Using a suitable press, install the ring gear. 28. Install the remaining bolts. 29. Remove the three bolts. 30. CAUTION: Position the three empty bolt holes downward. Position the differential case with the special tools into the differential carrier housing. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6115 31. Position the special tools. 32. Push and rock the ring gear into mesh with the pinion gear (zero backlash) and adjust the special tool to zero. 33. Move the ring gear away from the pinion gear as far as possible. Record the reading on the Differential Bearing Shim Selection Procedure Worksheet, Line B, in this procedure. 34. Remove the special tools. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6116 35. Remove the differential case and the special tools. 36. NOTE: Measure both of the differential bearing stand heights prior to installing them on the differential case. NOTE: Mark the left and right differential bearings before measuring them. Clamp the special tool base in a soft jawed vise with the bearing mounting surface above the surface of the vise. 37. Position the differential bearing assembly in the special tool, and tighten the tool. Part 2 of 2 38. Measure the differential bearing stand height. 1 Invert the special tool and bearing assembly in the vise. 2 Use a depth micrometer to measure and record the differential bearing stand height. Repeat the procedure for the other bearing. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6117 Differential Bearing Shim Selection Procedure Worksheet 39. Select appropriate differential bearing shims. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6118 Differential Shim Size Chart 40. Select the appropriate shim by the thickness or the stripe color. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6119 41. Install the three bolts. 42. CAUTION: Press against the bearing inner cone only. Using a suitable press and the special tool, install the differential bearings. 1 Position the appropriate differential bearing (RH or LH). 2 Using a suitable press and the special tool, install the differential bearing. Repeat the procedure for the other differential bearing. 43. NOTE: Make sure the indicator needle is in the spreader adapter hole. Install the special tools. 44. CAUTION: Overspreading can damage the axle housing. Spread the axle housing to the specification. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6120 45. CAUTION: Never attempt to drive the differential bearing shim in place. Permanent damage to the machined axle housing surfaces can occur. If removed, position the differential bearing shims. 1 Apply a light coating of Premium Long Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B to one side of the differential bearing shims to help hold them in place. 2 Position the differential bearing shims. 46. NOTE: Push the differential case downward to fully seat the differential bearing cups in the axle housing. Position the differential case assembly. 1 Position the differential bearing cups on the differential bearings. 2 Lower the differential case assembly in place between the differential bearing shims. 47. Install the bearing caps in their original positions and tighten with the housing still spread. 1 Position the bearing caps. 2 Install the bolts. 3 Remove the special tool. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6121 48. Install the special tool. 49. Measure the ring gear backlash at four places to obtain a consistent reading. 1 Mount the special tools on the indicator base. 2 Position the indicator needle and zero the indicator. 3 Turn the ring gear without turning the pinion gear and record the measurement. 50. NOTE: If the backlash is not within the specifications, correct it by increasing the thickness of one differential bearing shim and decreasing the thickness on the other differential bearing shim by the same amount. To increase the backlash, install a thicker differential bearing shim and a thinner differential bearing shim as shown. 51. To decrease the backlash, install a thicker differential bearing shim and a thinner differential bearing shim as shown. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6122 52. Liberally lubricate the axle shaft shift lever, and install a new O-ring. - Use Ford Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or WA-10 or equivalent meeting Ford specification ESE-M1C171-A. 53. Install the axle shaft shift lever. 1 Position the clutch fork. 2 Install the axle shaft shift lever. Align the manual shaft retaining pin holes. 54. Install the manual shaft retaining pin flush with the axle shaft shift lever. 55. Lift the axle shaft shift lever, and position the coupler shift selector gear, tapered end downward, into the clutch fork. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6123 56. Using the special tools, install the pilot bearing assembly into the axle cluster gear shaft. 57. Insert the axle cluster gear shaft through the coupler shift selector gear and engage the splines. 58. Coat the thrust washer with grease, and position it on the axle cluster gear shaft. - Use Premium Long Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B. 59. CAUTION: Remove all of the old liquid gasket, and make sure the machined surfaces are free of oil before applying the new silicone rubber. CAUTION: Install the axle housing tube within 15 minutes of applying the silicone, or it will be necessary to remove and reapply new sealant. If possible, allow one hour before filling with lubricant to make sure the silicone has cured. CAUTION: Do not allow any silicone rubber to squeeze inside during assembly. Fill the groove with Ford Black Silicone Rubber F4AZ-19562-B or equivalent meeting Ford specification WSE-M4G323-A1 and ESE-M46195-A. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6124 60. Assemble the axle housing tube. - Align the bolt holes and position the axle housing tube. - Position the axle identification tag. - Install the bolts. 61. Examine the axle shaft seal and bearing surface for damage. If necessary, polish the bearing surface with fine crocus cloth. 62. Insert the axle shaft and engage it with the side gear. 63. NOTE: Do not reuse the old snap ring. Push in on the axle shaft and install a new snap ring. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6125 64. Install the clutch shaft rod boot. 1 Fully extend the actuator motor shaft and plug the vacuum ports. 2 Position the front axle actuator motor assembly. 3 Install the clutch shaft rod boot. 65. With the actuator motor shaft fully extended and the vacuum ports plugged, engage the shift lever. 66. Seat the front axle actuator motor assembly and install the E-ring. 67. Seat the clutch shaft rod boot in the slot in the actuator housing. - Remove the plugs from the vacuum ports. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6126 68. NOTE: Install a new vacuum motor if any vacuum leakage is observed. NOTE: With the lever moved outboard, the axle is engaged and the axles will turn opposite of each other. With the lever moved inboard, the axle is disengaged and the axles will turn freely of each other. Verify the front axle actuator motor assembly operation (engage). Using the special tool, apply vacuum to the outer vacuum port to move the shift lever outboard. Rotate one axle shaft to verify engagement. 69. Verify the front axle actuator motor assembly operation (disengage). - Using the special tool, apply vacuum to the inner vacuum port to move the shift lever inboard. Rotate one axle to verify disengagement. 70. Remove the axle assembly from the Holding Fixture and place it on the bench. 71. CAUTION: Remove all of the oil liquid gasket, and make sure the machined surfaces are free of oil before applying the new silicone rubber. CAUTION: Install the differential housing cover within 15 minutes of applying the silicone, or it will be necessary to remove and reapply new sealant. If possible, allow one hour before filling with lubricant to make sure the silicone has cured. Fill the sealing groove on the differential housing cover with Ford Black Silicone Rubber F4AZ-19562-B or equivalent meeting Ford specification WSE-M4G323-A1 and ESE-M46195-A. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6127 72. Install the differential housing cover. 1 Position the differential housing cover. 2 Install the bolts. 73. Fill the differential carrier housing, and install the fill plug. - Use Motorcraft SAE 75W90 4x4 Axle Lubricant XY-75W90-QL or equivalent meeting Ford specification WSP-M2C201-A. - Be sure to tighten both the drain and fill plugs. 74. Install the front drive axle assembly, please refer to Transmission and Drivetrain/Differential Assembly/Service and Repair/Procedures/Front/ See: Removal & Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6128 Differential Case: Service and Repair Axle Tube Disassembly and Assembly Bushing-Carrier Removal 1. NOTE: It is not necessary to remove the axle assembly from the jack. Remove the front drive axle assembly. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6129 Special Tools 2. Position the carrier bushing removal tools. 1 Position Bushing Remover/Replacer Cup. 2 Position Draw bolt through Bushing Remover/Replacer Cup and the bushing. 3 Thread the Bushing Remover Adapter on the Draw bolt. 3. Tighten the Draw bolt to remove the carrier bushing. Installation 1. Position the carrier bushing and the carrier bushing installation tools. 1 Position the Gauge Ring on the outer face of the bushing flange. 2 Position the Bushing Replacer Collet over the Gauge Ring and the bushing flange. 3 Slide the Bushing Remover/Replacer Cup over the Bushing Replacer Collet. 4 Insert the Draw bolt. 5 Thread the Bushing Replacer Adapter on the Draw bolt. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6130 2. NOTE: The gauge ring will correctly locate the carrier bushing when the Bushing Replacer Collet bottoms out on the carrier. Tighten the Draw bolt until Bushing Replacer Collet contacts the carrier. Remove the tools. 3. Install the front drive axle assembly. Bushing-Cover Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6131 Special Tools Removal 1. Remove the front drive axle assembly. 2. Position the cover bushing removal tools. 1 Position the Bushing Remover. 2 Position the Bushing Remover/Replacer Cup. 3 Position the Draw bolt. 4 Thread the Bushing Remover on the Draw bolt. 3. Tighten the Draw bolt to remove the cover bushing. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6132 1. Position the differential cover bushing and differential cover bushing tools. 1 Position the differential cover bushing. 2 Position the Bushing Replacer Collet. 3 Position the Bushing Remover/Replacer Cup. 4 Position the Draw bolt. 5 Position the Bushing Replacer Adapter. 6 Thread Bushing Replacer on the Draw bolt. 2. To install the differential cover bushing, tighten the Draw bolt until the specified gap is reached between the cover ear and the bushing flange. Use a feeler gauge to verify the correct gap length. Remove the tools. 3. Install the front drive axle assembly. Bushing-Tube Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6133 Special Tools Removal 1. Remove the front drive axle assembly. 2. Position the tube bushing removal tools. 1 Position the Bushing Remover/Replacer Cup. 2 Position the Draw bolt. 3 Thread the Bushing Remover Adapter on the Draw bolt. 3. Tighten the Draw bolt to remove the tube bushing. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6134 1. Position the tube bushing and the tube bushing installation tools. 1 Position the tube bushing. 2 Position the Gauge Ring. 3 Position the Bushing Replacer Collet. 4 Position the Bushing Remover/Replacer Cup. 5 Position the Draw bolt. 6 Thread the Bushing Replacer on the Draw bolt. 2. Tighten the Draw bolt until the Bushing Replacer Collet contacts the axle tube. - Remove the tools. 3. Install the front drive axle assembly. Axle Tube Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6135 Special Tools Disassembly 1. Remove the front drive axle assembly. 2. Position a suitable drain pan, and remove the axle housing tube. 3. Secure the axle housing tube in a vise. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6136 4. Remove the gasket from the sealing groove and flange face. 5. Remove the axle clutch gear. 1 Push the axle shaft inward, and remove the snap ring. 2 Remove the axle clutch gear. 6. Remove the steel thrust washer and the tanged thrust washer. 7. Remove the axle shaft. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6137 8. Using the special tools, remove the inner bearing. 9. Reposition the axle housing tube in the vise, and remove the axle shaft dust seal. 10. Using the special tools, remove the outer bearing. 11. CAUTION: Be careful not to damage the seal or bearing surfaces. If necessary, remove the axle shaft dust deflector. Assembly Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6138 1. CAUTION: The arrow marked "Inboard" on the Needle Bearing Replacer tool must point toward the axle housing when installing the inner bearing. Using the special tools, install the inner bearing. 1 Position the axle housing tube in a vise. 2 Position the inner bearing. 3 Using the special tools, install the inner bearing. 2. CAUTION: The arrow marked "Outboard" on the Needle Bearing Replacer tool must point toward the axle housing when installing the outer bearing. NOTE: When the tool flange bottoms out on the tube flange, bearing installation is correct. Using the special tools, install the outer bearing. 1 Position the axle housing tube in the vise. 2 Position the outer bearing. 3 Using the special tools, install the outer bearing. 3. Using the special tools, install the axle shaft dust seal. - Make sure the axle shaft dust seal flange is flush with the axle housing tube. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6139 4. If removed, position the axle shaft dust deflector for installation. 1 Position the axle bearing seal plate on the press bed. 2 Position the special tool. 3 Position the axle shaft dust deflector. 5. If removed, use a suitable press to press the axle shaft dust deflector on the axle shaft. 6. Insert the axle shaft into the axle housing tube. 7. Lubricate the steel thrust washer. - Use Premium Long Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B. 8. Install the tanged thrust washer and the steel thrust washer. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6140 9. Install the axle clutch gear. 10. Push in on the axle shaft and install a new snap ring. 11. CAUTION: Remove all of the old liquid gasket, and make sure the machined surfaces are free of oil before applying the new silicone rubber. CAUTION: Install the axle housing tube within 15 minutes of applying the silicone, or it will be necessary to remove and reapply new sealant. If possible, allow one hour before filling with lubricant to make sure the silicone sealant has cured. CAUTION: Do not allow any silicone rubber to squeeze inside during assembly. Fill the groove with Ford Black Silicone Rubber F4AZ-19562-B or equivalent meeting Ford specification WSE-M4G323-A1 and ESE-M4G195-A. 12. Assemble the axle housing tube. - Align the bolt holes and position the axle housing tube. - Position the axle identification tag. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal & Installation > Page 6141 - Install the bolts. 13. Install the front drive axle assembly. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > Customer Interest for Differential Clutch: > 00-8-4 > Apr > 00 > Differential Chattering On Turns Differential Clutch: Customer Interest Differential - Chattering On Turns Article No. 00-8-4 DATE: 04/17/2000 ^ NOISE - "CHATTERING" FROM REAR AXLE HEARD ON TURNS OR WHEN CORNERING VEHICLES WITH LIMITED SLIP AXLE ^ AXLE - LIMITED SLIP - REAR AXLE "CHATTERING" NOISE ON TURNS OR WHEN CORNERING FORD: 1999-2000 E-150, EXPEDITION, F-150 LINCOLN: 1999-2000 NAVIGATOR ISSUE A "chattering" noise from the rear axle may be heard when turning or cornering. This may be due to differentials containing clutch packs that have been gauged too tightly. ACTION Install new Traction-Lok Clutch Pack Kit. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Confirm axle chatter with road test. 2. Once axle chatter has been confirmed, remove and discard old clutch packs, shims and Belleville springs. Refer to the appropriate Workshop Manual for details. NOTE: Subtract O.25 mm (0.010") from feeler gauge reading taken during shim selection using service tools and procedures indicated on instruction sheets packaged with kits. 3. Install Clutch Pack Kit F75Z-4947-AA for 9.75" ring gear Traction-Lok axles or Clutch Pack Kit F75Z-4947-AB for 10.25 " ring gear Traction-Lok axles. For ring gear size and differential type, see embossed metal tag attached to rear axle cover. Refer to the appropriate Workshop Manual for details. PART NUMBER PART NAME F752-4947-AA Clutch Pack Kit (9.75" Ring Gear) F75Z-4947-AB Clutch Pack Kit (10.25" Ring Gear) OTHER APPLICABLE ARTICLES: NONE Operation Information Operarion numbers description and times Dealer Coding Dealer part number and condition code Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > Customer Interest for Differential Clutch: > 00-8-4 > Apr > 00 > Differential Chattering On Turns > Page 6150 Oasis Coding Oasis codes WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Clutch: > 00-8-4 > Apr > 00 > Differential - Chattering On Turns Differential Clutch: All Technical Service Bulletins Differential - Chattering On Turns Article No. 00-8-4 DATE: 04/17/2000 ^ NOISE - "CHATTERING" FROM REAR AXLE HEARD ON TURNS OR WHEN CORNERING VEHICLES WITH LIMITED SLIP AXLE ^ AXLE - LIMITED SLIP - REAR AXLE "CHATTERING" NOISE ON TURNS OR WHEN CORNERING FORD: 1999-2000 E-150, EXPEDITION, F-150 LINCOLN: 1999-2000 NAVIGATOR ISSUE A "chattering" noise from the rear axle may be heard when turning or cornering. This may be due to differentials containing clutch packs that have been gauged too tightly. ACTION Install new Traction-Lok Clutch Pack Kit. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Confirm axle chatter with road test. 2. Once axle chatter has been confirmed, remove and discard old clutch packs, shims and Belleville springs. Refer to the appropriate Workshop Manual for details. NOTE: Subtract O.25 mm (0.010") from feeler gauge reading taken during shim selection using service tools and procedures indicated on instruction sheets packaged with kits. 3. Install Clutch Pack Kit F75Z-4947-AA for 9.75" ring gear Traction-Lok axles or Clutch Pack Kit F75Z-4947-AB for 10.25 " ring gear Traction-Lok axles. For ring gear size and differential type, see embossed metal tag attached to rear axle cover. Refer to the appropriate Workshop Manual for details. PART NUMBER PART NAME F752-4947-AA Clutch Pack Kit (9.75" Ring Gear) F75Z-4947-AB Clutch Pack Kit (10.25" Ring Gear) OTHER APPLICABLE ARTICLES: NONE Operation Information Operarion numbers description and times Dealer Coding Dealer part number and condition code Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Clutch: > 00-8-4 > Apr > 00 > Differential - Chattering On Turns > Page 6156 Oasis Coding Oasis codes WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > 8.8 Inch Ring Gear Differential Cover: Service and Repair 8.8 Inch Ring Gear Removal 1. Raise and support the vehicle. 2. NOTE: Empty the lubricant into a clean container for reuse. Remove the differential housing cover. 1 Remove the 10 differential housing cover bolts and drain the lubricant from the rear axle housing. 2 Remove the differential housing cover. Installation 1. CAUTION: Make sure the machined surfaces on both the rear axle housing and the differential housing cover are clean and free of oil before installing the new silicone sealant. The inside of the rear axle must be covered when cleaning the machined surface to prevent contamination. Clean the gasket mating surface of the rear axle and the differential housing cover. 2. Apply a new continuous bead of sealant to the differential housing cover. - Use Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specifications ESB-M4G92-A and ESE-M4G195-A. 3. NOTE: The differential housing cover must be installed within 15 minutes of application of the silicone, or new sealant must be applied. If possible, allow one hour before filling with lubricant to make sure the silicone sealant has properly cured. Install the differential housing cover. 1 Install the differential housing cover. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6161 2 Install the 10 differential housing cover bolts. 4. CAUTION: For Traction-Lok axles, first fill the rear axle with 118 ml (4 oz) of specified Ford Friction Modifier. NOTE: Service refill capacities are determined by filling the rear axle to the level shown. Fill the rear axle with 2.4 liters (5.5 pints) of Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A and install the filler plug. 5. Lower the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6162 Differential Cover: Service and Repair 9.75 Inch Ring Gear Removal 1. Raise and support the vehicle. 2. NOTE: Empty the lubricant into a clean container for reuse. Remove the differential housing cover. 1 Remove the 12 differential housing cover bolts, and drain the lubricant from the rear axle housing. 2 Remove the differential housing cover. Installation 1. CAUTION: Make sure the machined surfaces on both the rear axle housing and the differential housing cover are clean and free of oil before applying the new silicone sealant. The inside of the rear axle must be covered when cleaning the machined surface to prevent contamination. Clean the gasket mating surface of the rear axle and the differential housing cover. 2. Apply a new, continuous bead of sealant to the differential housing cover. - Use Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specifications ESB-M4G92-A and ESE-M4G195-A. 3. NOTE: The differential housing cover must be installed within 15 minutes of application of the silicone, or new sealant must be applied. If possible, allow 1 hour before filling with lubricant to ensure the silicone sealant has properly cured. Install the differential housing cover and tighten the differential housing cover bolts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6163 4. CAUTION: For Traction-Lok axles, first fill the rear axle with 118 ml (4 ounces) of specified Ford Additive Friction Modifier. NOTE: Service refill capacities are determined by filling the rear axle with the specified lubricant to the specified level below the bottom of the filler hole. Fill the rear axle to the level shown with Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A, and install the filler plug. 5. Lower the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential Differential Axle Housing: Service and Repair Front Differential Removal & Installation Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. With the transmission in Neutral, raise and support the vehicle. 2. Index-mark the front driveshaft to the axle universal joint flange. 3. CAUTION: Do not allow the driveshaft to hang unsupported. Disconnect and support the front driveshaft. 1 Remove the four bolts. 2 Carefully disconnect and support the front driveshaft. 4. CAUTION: Do not allow the halfshaft to hang unsupported. Remove the six bolts and disconnect the front drive halfshaft. Repeat Step 4 for the opposite side. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6168 5. Disconnect the vacuum lines and the front axle vent tube. 6. Use a high-lift Jack to support the axle assembly. 7. Remove the front differential support. 1 Remove the nut and bolt. 2 Remove the nuts and bolts. 3 Remove the front differential support. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6169 8. Remove the nut and bolt. 9. Remove the nut and bolt. 10. Carefully lower the front drive axle assembly. Installation 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6170 Disassembly Part 1 Of 5 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6171 Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6172 Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6173 Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6174 Special Tools Special Tools 1. Remove the front drive axle assembly, please refer to Transmission and Drivetrain/Differential Assembly/Service and Repair/Procedures/Front/ See: Removal & Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6175 2. Remove the differential housing cover. 1 Remove the drain plug. 2 Drain the fluid. 3 Remove the bolts. 4 Remove the differential housing cover. 3. CAUTION: The fixture mounting bolts must have the minimum specified thread engagement in the carrier. Install the special tool. 4. Unseat the clutch shaft rod boot. 5. Remove the E-ring. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6176 6. Disconnect the front axle actuator motor assembly. 1 Fully extend the actuator motor shaft. 2 Plug the vacuum ports. 3 Pull outward on the front axle actuator motor assembly. 4 Push the front axle actuator motor assembly to disconnect the shift lever from the slot in the actuator motor shaft. 7. Remove the clutch shaft rod boot, and the front axle actuator motor assembly. 1 Remove the clutch shaft rod boot. 2 Remove the front axle actuator motor assembly. 8. Remove the axle housing tube, please refer to Transmission and Drivetrain/Differential Assembly/Service and Repair/Procedures/Front/ See: Axle Tube Disassembly and Assembly 9. Remove the thrust washer. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6177 10. Remove the axle cluster gear shaft. 11. CAUTION: Use a vise with soft jaws. Using the special tool, remove the pilot bearing assembly from the axle cluster gear shaft. 1 Position the axle cluster gear shaft in the vise. 2 Using the special tool, remove the pilot bearing assembly. 12. Lift the shift lever, and remove the coupler shift selector gear. 13. NOTE: There is enough clearance in the casting to remove the manual shaft retaining pin. If necessary, remove the shift lever and the clutch fork. 1 Drive the manual shaft retaining pin through the clutch fork. 2 Remove the shift lever and the clutch fork. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6178 14. Remove and discard the O-ring. 15. Remove the axle shaft. 1 Remove the snap ring. 2 Remove the axle shaft. 16. CAUTION: The housing spreader adapter bolts must have the minimum specified thread engagement in the carrier. Install the special tools. 17. Position the special tool on the spreader adapters. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6179 18. If necessary, adjust the special tool to provide clearance for the shift lever. 19. Install the special tools. Position the adapter tip in the spreader adapter hole. 20. CAUTION: Overspreading can damage the axle housing. Spread the axle housing to the specification. 1 Adjust the special tool to zero. 2 Tighten the housing spreader screw to spread the axle housing to the specification. 3 Remove the special tool. 21. CAUTION: Mark the differential bearing caps Top or Bottom and LH or RH appropriately before removing them. Always install the bearing caps in their original place and position. Mark and remove the differential bearing caps, 1 Remove the bolts. 2 Remove the differential bearing caps. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6180 22. CAUTION: Use wood blocks to avoid axle housing damage. Remove the differential assembly from the axle housing. 1 Position the wood blocks. 2 Position and push down on the two pry bars. 3 Remove the differential assembly. 4 Remove the special tool. 23. Index-mark the axle universal joint flange to the pinion stem. 24. Install the special tool, and loosen, but do not remove the pinion nut. 25. With the pinion nut still engaged by a few threads, use the special tool to separate the axle universal joint flange from the pinion gear. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6181 26. Using the special tool and a soft hammer, remove the pinion gear. 1 Install the special tool. 2 Hold the pinion gear inside the carrier housing. 3 Using a soft face hammer, remove the pinion gear from the carrier housing. 27. Discard the drive pinion collapsible spacer. 28. CAUTION: Do not damage the carrier housing while removing the pinion seal. Remove the pinion seal and slinger. Pry up on the seal flange. Install gripping pliers, and strike with a hammer to remove the seal. 29. Remove the outer pinion bearing. 30. Using the special tools, remove the inner pinion bearing cup. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6182 31. NOTE: The pinion bearing oil baffle aids in bearing lubrication. Normally, it is not necessary to remove the baffle. If necessary, remove the pinion bearing oil baffle. 32. Remove the outer pinion bearing cup by tapping alternately on each side to prevent the cup from cocking. 33. Using the special tool and a suitable press, remove the pinion bearing. 34. NOTE: A drive pinion bearing adjustment shim sits under the pinion bearing. Use a micrometer to measure the shim thickness. Record the measurement for comparison to the shim gauge reading taken prior to installing the pinion bearing. Remove and measure the drive pinion bearing adjustment shim. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6183 35. Remove the ten bolts and the ring gear. - Use a drift punch to separate the ring gear from the differential case. 36. Using the special tools, remove the differential bearings. Part 1 of 2 1. CAUTION: Do not omit the pinion bearing oil baffle; bearing failure can result. If removed, position the baffle on the special tool. 2. Using the special tool, install the baffle. 3. NOTE: Always install new pinion bearings when installing new pinion bearing cups. Lightly oil the new pinion bearing cups and pinion bearings with Motorcraft SAE75W90 4x4 Axle Lubricant XY-75W90-QL or equivalent meeting Ford specification WSP-M2C201-A. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6184 4. Using the special tool, install the bearing cups. 5. NOTE: You must use the pinion bearings assembled in this procedure step at final assembly. Assemble and position the special tools and the pinion bearings in the carrier housing. 1 Position the Screw. 2 Position the Aligning Adapter. 3 Position the pinion bearing. 4 Position the Gauge Disc. 5 Position the Gauge Block. 6 Position the pinion bearing. 7 Thread on the Handle. 6. NOTE: This step duplicates final pinion bearing preload. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6185 Tighten the special tool to the specification to simulate bearing preload. 7. NOTE: Offset the Gauge Block to obtain an accurate reading. Rotate the Gauge Block several half-turns to make sure the pinion bearings seat correctly, and position the Gauge Block. 8. Install the special tool. 1 Position the special tool. 2 Install the differential bearing caps. 3 Install the bolts. 9. NOTE: Use only flat, clean drive pinion bearing adjustment shims. NOTE: Selection of a shim that is too thick results in a deep tooth contact at final assembly of integral axle assemblies. Do not attempt to force the shim between the Gauge Block and the Gauge Tube. A slight drag indicates correct shim selection. Use a drive pinion bearing adjustment shim as a gauge for shim selection. Check the adjustment shim thickness between the Gauge Block and the Gauge Tube. - After determining the correct shim thickness, remove the special tools. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6186 10. NOTE: You must use the same pinion bearings from the previous steps. Install the pinion bearing. Place the drive pinion bearing adjustment shim on the pinion gear. - Using a suitable press and the special tool, press the pinion bearing until it is firmly seated on the pinion gear. 11. Place a new drive pinion collapsible spacer on the pinion stem. 12. Install the outer pinion bearing. 13. Install the slinger. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6187 14. NOTE: Coat the lips of the pinion seal with Motorcraft SAE 75W90 4x4 Axle Lubricant XY-75W90-QL or equivalent meeting Ford specification WSP-M2C201-A. Place the pinion seal on the special tool. 15. Place the special tool and seal in the pinion seal bore and drive the seal into place. 16. Lightly lubricate the pinion gear splines with Motorcraft SAE 75W90 4x4 Axle Lubricant XY-75W90-QL or equivalent meeting Ford specification WSP-M2C201-A. 17. Position the pinion gear. 18. CAUTION: Never install the axle universal joint flange with a hammer. NOTE: Disregard the scribe marks if installing a new flange. Align the index-marks and position the universal joint flange on the pinion shaft. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6188 19. NOTE: Rotate the pinion gear occasionally to make sure the pinion bearings seat correctly. Using the special tool, install the axle universal joint flange. 20. Apply a small amount of lubricant to the washer side of the new pinion nut, and install the nut. 21. CAUTION: Do not loosen the pinion nut to reduce preload under any circumstance. If it is necessary to reduce preload, install a new drive pinion collapsible spacer and pinion nut. Install the special tool, and tighten the pinion nut. Rotate the pinion gear occasionally to make sure the pinion bearings are seating correctly. Take frequent pinion bearing torque preload readings by rotating the pinion gear with an Nm (inch/pound) torque wrench. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6189 22. CAUTION: Use extreme care not to damage the aluminum differential carrier housing while performing the following procedure steps. CAUTION: The special tools are marked LH and RH. Install them accordingly. Install the special tools. 23. Install the differential case with the Master Bearings in the differential carrier. 24. NOTE: Repeat this step until you obtain a consistent reading. Measure the total end play. 1 Position the special tools. 2 Position the indicator tip on the machined surface and adjust it to measure full travel. 3 Push the differential case left and right (as far as possible). 4 Measure the total end play and record the reading on the Differential Bearing Shim Selection Procedure Worksheet, Line A, in this procedure. 25. Remove the special tools and the differential case. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6190 26. Use a fine flat file to remove any burrs or nicks from the ring gear mounting surface. 27. Install the ring gear. 1 Position three bolts to align the holes in the ring gear and the differential case. 2 Using a suitable press, install the ring gear. 28. Install the remaining bolts. 29. Remove the three bolts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6191 30. CAUTION: Position the three empty bolt holes downward. Position the differential case with the special tools into the differential carrier housing. 31. Position the special tools. 32. Push and rock the ring gear into mesh with the pinion gear (zero backlash) and adjust the special tool to zero. 33. Move the ring gear away from the pinion gear as far as possible. Record the reading on the Differential Bearing Shim Selection Procedure Worksheet, Line B, in this procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6192 34. Remove the special tools. 35. Remove the differential case and the special tools. 36. NOTE: Measure both of the differential bearing stand heights prior to installing them on the differential case. NOTE: Mark the left and right differential bearings before measuring them. Clamp the special tool base in a soft jawed vise with the bearing mounting surface above the surface of the vise. 37. Position the differential bearing assembly in the special tool, and tighten the tool. Part 2 of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6193 38. Measure the differential bearing stand height. 1 Invert the special tool and bearing assembly in the vise. 2 Use a depth micrometer to measure and record the differential bearing stand height. Repeat the procedure for the other bearing. Differential Bearing Shim Selection Procedure Worksheet 39. Select appropriate differential bearing shims. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6194 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6195 Differential Shim Size Chart 40. Select the appropriate shim by the thickness or the stripe color. 41. Install the three bolts. 42. CAUTION: Press against the bearing inner cone only. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6196 Using a suitable press and the special tool, install the differential bearings. 1 Position the appropriate differential bearing (RH or LH). 2 Using a suitable press and the special tool, install the differential bearing. Repeat the procedure for the other differential bearing. 43. NOTE: Make sure the indicator needle is in the spreader adapter hole. Install the special tools. 44. CAUTION: Overspreading can damage the axle housing. Spread the axle housing to the specification. 45. CAUTION: Never attempt to drive the differential bearing shim in place. Permanent damage to the machined axle housing surfaces can occur. If removed, position the differential bearing shims. 1 Apply a light coating of Premium Long Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B to one side of the differential bearing shims to help hold them in place. 2 Position the differential bearing shims. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6197 46. NOTE: Push the differential case downward to fully seat the differential bearing cups in the axle housing. Position the differential case assembly. 1 Position the differential bearing cups on the differential bearings. 2 Lower the differential case assembly in place between the differential bearing shims. 47. Install the bearing caps in their original positions and tighten with the housing still spread. 1 Position the bearing caps. 2 Install the bolts. 3 Remove the special tool. 48. Install the special tool. 49. Measure the ring gear backlash at four places to obtain a consistent reading. 1 Mount the special tools on the indicator base. 2 Position the indicator needle and zero the indicator. 3 Turn the ring gear without turning the pinion gear and record the measurement. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6198 50. NOTE: If the backlash is not within the specifications, correct it by increasing the thickness of one differential bearing shim and decreasing the thickness on the other differential bearing shim by the same amount. To increase the backlash, install a thicker differential bearing shim and a thinner differential bearing shim as shown. 51. To decrease the backlash, install a thicker differential bearing shim and a thinner differential bearing shim as shown. 52. Liberally lubricate the axle shaft shift lever, and install a new O-ring. - Use Ford Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or WA-10 or equivalent meeting Ford specification ESE-M1C171-A. 53. Install the axle shaft shift lever. 1 Position the clutch fork. 2 Install the axle shaft shift lever. Align the manual shaft retaining pin holes. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6199 54. Install the manual shaft retaining pin flush with the axle shaft shift lever. 55. Lift the axle shaft shift lever, and position the coupler shift selector gear, tapered end downward, into the clutch fork. 56. Using the special tools, install the pilot bearing assembly into the axle cluster gear shaft. 57. Insert the axle cluster gear shaft through the coupler shift selector gear and engage the splines. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6200 58. Coat the thrust washer with grease, and position it on the axle cluster gear shaft. - Use Premium Long Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B. 59. CAUTION: Remove all of the old liquid gasket, and make sure the machined surfaces are free of oil before applying the new silicone rubber. CAUTION: Install the axle housing tube within 15 minutes of applying the silicone, or it will be necessary to remove and reapply new sealant. If possible, allow one hour before filling with lubricant to make sure the silicone has cured. CAUTION: Do not allow any silicone rubber to squeeze inside during assembly. Fill the groove with Ford Black Silicone Rubber F4AZ-19562-B or equivalent meeting Ford specification WSE-M4G323-A1 and ESE-M46195-A. 60. Assemble the axle housing tube. - Align the bolt holes and position the axle housing tube. - Position the axle identification tag. - Install the bolts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6201 61. Examine the axle shaft seal and bearing surface for damage. If necessary, polish the bearing surface with fine crocus cloth. 62. Insert the axle shaft and engage it with the side gear. 63. NOTE: Do not reuse the old snap ring. Push in on the axle shaft and install a new snap ring. 64. Install the clutch shaft rod boot. 1 Fully extend the actuator motor shaft and plug the vacuum ports. 2 Position the front axle actuator motor assembly. 3 Install the clutch shaft rod boot. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6202 65. With the actuator motor shaft fully extended and the vacuum ports plugged, engage the shift lever. 66. Seat the front axle actuator motor assembly and install the E-ring. 67. Seat the clutch shaft rod boot in the slot in the actuator housing. - Remove the plugs from the vacuum ports. 68. NOTE: Install a new vacuum motor if any vacuum leakage is observed. NOTE: With the lever moved outboard, the axle is engaged and the axles will turn opposite of each other. With the lever moved inboard, the axle is disengaged and the axles will turn freely of each other. Verify the front axle actuator motor assembly operation (engage). Using the special tool, apply vacuum to the outer vacuum port to move the shift lever outboard. Rotate one axle shaft to verify engagement. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6203 69. Verify the front axle actuator motor assembly operation (disengage). - Using the special tool, apply vacuum to the inner vacuum port to move the shift lever inboard. Rotate one axle to verify disengagement. 70. Remove the axle assembly from the Holding Fixture and place it on the bench. 71. CAUTION: Remove all of the oil liquid gasket, and make sure the machined surfaces are free of oil before applying the new silicone rubber. CAUTION: Install the differential housing cover within 15 minutes of applying the silicone, or it will be necessary to remove and reapply new sealant. If possible, allow one hour before filling with lubricant to make sure the silicone has cured. Fill the sealing groove on the differential housing cover with Ford Black Silicone Rubber F4AZ-19562-B or equivalent meeting Ford specification WSE-M4G323-A1 and ESE-M46195-A. 72. Install the differential housing cover. 1 Position the differential housing cover. 2 Install the bolts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6204 73. Fill the differential carrier housing, and install the fill plug. - Use Motorcraft SAE 75W90 4x4 Axle Lubricant XY-75W90-QL or equivalent meeting Ford specification WSP-M2C201-A. - Be sure to tighten both the drain and fill plugs. 74. Install the front drive axle assembly, please refer to Transmission and Drivetrain/Differential Assembly/Service and Repair/Procedures/Front/ See: Removal & Installation Bushing-Carrier Removal 1. NOTE: It is not necessary to remove the axle assembly from the jack. Remove the front drive axle assembly. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6205 Special Tools 2. Position the carrier bushing removal tools. 1 Position Bushing Remover/Replacer Cup. 2 Position Draw bolt through Bushing Remover/Replacer Cup and the bushing. 3 Thread the Bushing Remover Adapter on the Draw bolt. 3. Tighten the Draw bolt to remove the carrier bushing. Installation 1. Position the carrier bushing and the carrier bushing installation tools. 1 Position the Gauge Ring on the outer face of the bushing flange. 2 Position the Bushing Replacer Collet over the Gauge Ring and the bushing flange. 3 Slide the Bushing Remover/Replacer Cup over the Bushing Replacer Collet. 4 Insert the Draw bolt. 5 Thread the Bushing Replacer Adapter on the Draw bolt. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6206 2. NOTE: The gauge ring will correctly locate the carrier bushing when the Bushing Replacer Collet bottoms out on the carrier. Tighten the Draw bolt until Bushing Replacer Collet contacts the carrier. Remove the tools. 3. Install the front drive axle assembly. Bushing-Cover Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6207 Special Tools Removal 1. Remove the front drive axle assembly. 2. Position the cover bushing removal tools. 1 Position the Bushing Remover. 2 Position the Bushing Remover/Replacer Cup. 3 Position the Draw bolt. 4 Thread the Bushing Remover on the Draw bolt. 3. Tighten the Draw bolt to remove the cover bushing. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6208 1. Position the differential cover bushing and differential cover bushing tools. 1 Position the differential cover bushing. 2 Position the Bushing Replacer Collet. 3 Position the Bushing Remover/Replacer Cup. 4 Position the Draw bolt. 5 Position the Bushing Replacer Adapter. 6 Thread Bushing Replacer on the Draw bolt. 2. To install the differential cover bushing, tighten the Draw bolt until the specified gap is reached between the cover ear and the bushing flange. Use a feeler gauge to verify the correct gap length. Remove the tools. 3. Install the front drive axle assembly. Bushing-Tube Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6209 Special Tools Removal 1. Remove the front drive axle assembly. 2. Position the tube bushing removal tools. 1 Position the Bushing Remover/Replacer Cup. 2 Position the Draw bolt. 3 Thread the Bushing Remover Adapter on the Draw bolt. 3. Tighten the Draw bolt to remove the tube bushing. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6210 1. Position the tube bushing and the tube bushing installation tools. 1 Position the tube bushing. 2 Position the Gauge Ring. 3 Position the Bushing Replacer Collet. 4 Position the Bushing Remover/Replacer Cup. 5 Position the Draw bolt. 6 Thread the Bushing Replacer on the Draw bolt. 2. Tighten the Draw bolt until the Bushing Replacer Collet contacts the axle tube. - Remove the tools. 3. Install the front drive axle assembly. Axle Tube Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6211 Special Tools Disassembly 1. Remove the front drive axle assembly. 2. Position a suitable drain pan, and remove the axle housing tube. 3. Secure the axle housing tube in a vise. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6212 4. Remove the gasket from the sealing groove and flange face. 5. Remove the axle clutch gear. 1 Push the axle shaft inward, and remove the snap ring. 2 Remove the axle clutch gear. 6. Remove the steel thrust washer and the tanged thrust washer. 7. Remove the axle shaft. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6213 8. Using the special tools, remove the inner bearing. 9. Reposition the axle housing tube in the vise, and remove the axle shaft dust seal. 10. Using the special tools, remove the outer bearing. 11. CAUTION: Be careful not to damage the seal or bearing surfaces. If necessary, remove the axle shaft dust deflector. Assembly Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6214 1. CAUTION: The arrow marked "Inboard" on the Needle Bearing Replacer tool must point toward the axle housing when installing the inner bearing. Using the special tools, install the inner bearing. 1 Position the axle housing tube in a vise. 2 Position the inner bearing. 3 Using the special tools, install the inner bearing. 2. CAUTION: The arrow marked "Outboard" on the Needle Bearing Replacer tool must point toward the axle housing when installing the outer bearing. NOTE: When the tool flange bottoms out on the tube flange, bearing installation is correct. Using the special tools, install the outer bearing. 1 Position the axle housing tube in the vise. 2 Position the outer bearing. 3 Using the special tools, install the outer bearing. 3. Using the special tools, install the axle shaft dust seal. - Make sure the axle shaft dust seal flange is flush with the axle housing tube. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6215 4. If removed, position the axle shaft dust deflector for installation. 1 Position the axle bearing seal plate on the press bed. 2 Position the special tool. 3 Position the axle shaft dust deflector. 5. If removed, use a suitable press to press the axle shaft dust deflector on the axle shaft. 6. Insert the axle shaft into the axle housing tube. 7. Lubricate the steel thrust washer. - Use Premium Long Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B. 8. Install the tanged thrust washer and the steel thrust washer. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6216 9. Install the axle clutch gear. 10. Push in on the axle shaft and install a new snap ring. 11. CAUTION: Remove all of the old liquid gasket, and make sure the machined surfaces are free of oil before applying the new silicone rubber. CAUTION: Install the axle housing tube within 15 minutes of applying the silicone, or it will be necessary to remove and reapply new sealant. If possible, allow one hour before filling with lubricant to make sure the silicone sealant has cured. CAUTION: Do not allow any silicone rubber to squeeze inside during assembly. Fill the groove with Ford Black Silicone Rubber F4AZ-19562-B or equivalent meeting Ford specification WSE-M4G323-A1 and ESE-M4G195-A. 12. Assemble the axle housing tube. - Align the bolt holes and position the axle housing tube. - Position the axle identification tag. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6217 - Install the bolts. 13. Install the front drive axle assembly. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6218 Differential Axle Housing: Service and Repair Rear Differential Removal and Installation Part 1 Of 2 Removal 1. Remove the differential housing cover and drain the rear axle. 2. Remove the axle shafts. 3. Wipe the lubricant from the internal working parts and visually inspect the parts for wear or damage. 4. Rotate the differential case to see if there is any roughness which would indicate damaged bearings or gears. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6219 5. NOTE: There is a space between the anti-lock speed sensor ring and the ring gear for measuring ring gear back face runout. Position the special tool and inspect ring gear backlash and ring gear back face runout. 6. CAUTION: Mark the position of the bearing caps, as arrows may not be visible. The bearing caps must be installed in their identical locations and positions. Loosen the differential case. 1 Remove the four bearing cap bolts. 2 Remove the two bearing caps. 7. WARNING: Be careful not to allow the differential case to fall. CAUTION: Place a wood block between the pry bar and the rear axle housing to protect the machined surface from damage. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6220 Using pry bars and the wood blocks, remove the differential case from the rear axle housing. 8. Remove the 10 ring gear bolts. 9. CAUTION: Care should be taken not to damage the ring bolt hole threads. NOTE: The anti-lock speed sensor ring cannot be reused once removed. Insert a punch in the bolt holes and drive off the ring gear and, if necessary, the anti-lock speed sensor ring. 10. Install the differential case. - Position the differential case assembly, including the bearing cups and shims, in the rear axle housing. Install the differential bearing caps and the differential bearing cap bolts. 11. Position the special tool. 1 Rotate the differential case to ensure the differential bearings are correctly seated. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6221 2 Install the special tool. 12. NOTE: If runout is less than specification, install a new ring gear and pinion. If runout exceeds specification, the ring gear is true and the concern is due to either a damaged differential case or differential bearings. Inspect the differential bearings. If the differential bearings are not damaged, replace both the differential case and the differential bearings. Measure the differential case runout without the ring gear. 1 Rotate the differential case. 2 Check and note the differential case runout. 13. Remove the differential case from the rear axle housing and remove the differential bearings using the special tools. 14. Using the special tool install the new differential bearings on the differential case. 15. Install the differential case. Position the differential case assembly, including the bearing cups and shims in the rear axle housing. Tighten bearing caps to specifications. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6222 16. Measure the differential case runout without the ring gear, and check the case runout again with the new differential bearings. - If the runout is now less than the specification shown, use the new differential bearings for assembly. - If the runout is still excessive, the differential case is damaged and must be replaced. Installation 1. CAUTION: Make sure that the notches on the case flange and the anti-lock speed sensor ring are aligned. Press a new anti-lock speed sensor ring, if removed, and the ring gear on the differential case. Align the notch on the differential case flange with the notch on the anti-lock speed sensor ring, 2. Install the ring gear bolts. - Apply Stud and Bearing Mount E0AZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to ring gear bolts. 3. With pinion depth set and pinion installed, place the differential case in the rear axle housing. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6223 4. Install a shim on the left side. 5. CAUTION: Mark the position of the bearing caps as arrows may not be visible. The bearing caps must be installed in their identical locations and positions. NOTE: Apply pressure toward the left side to make sure the left bearing cap is seated. Install the left bearing cap and loosely install the bearing cap bolts. 6. Install progressively larger shims on the right side until the largest shim selected can be assembled by hand. 7. Install the right side bearing cap and tighten the left side and right side bolts to specification. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6224 8. Rotate the differential case to make sure it rotates freely. 9. Using the special tool, measure the ring gear backlash. - If the backlash is within specification, go to Step 14. - If a zero backlash condition occurs, go to Step 10. - If the backlash is not within specification, go to Step 11. 10. If a zero backlash condition occurs, add 0.51 mm (0.020 inch) to the RH side and subtract 0.51 mm (0.020 inch) from the LH side to allow backlash indication. Check the backlash. Repeat Step 9. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6225 11. To increase or decrease the backlash, remove the bearing caps and install a thicker shim or a thinner shim as shown. - If the backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness of the other differential bearing shim by the same amount. 12. Rotate the differential several times to make sure the differential bearings are correctly seated. 13. Using the special tool, recheck the backlash. - If the backlash is within specification, go to Step 14. If the backlash is not within specification, repeat Step 9. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6226 14. Remove the bearing caps and bolts. - To establish differential bearing preload, increase both left and right shim sizes by the specification. - Use the special tool to ensure that the differential bearing shims are fully seated and the assembly turns freely. 15. Install the bearing caps and bearing cap bolts. 16. Using the special tool, recheck the backlash. 17. Install the axle shafts. Front Disassembly 1. Remove the differential assembly from the differential carrier housing. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6227 2. Remove the ring gear. - Remove the ten bolts. - Use a drift punch to separate the ring gear from the differential case. 3. Remove the differential pinion shaft bolt. 4. Remove the differential pinion shaft. 5. Remove the differential pinion thrust washers and the differential pinion gears. 1 Rotate the differential pinion gears to the differential case window, and remove them. 2 Separate the thrust washers from the gears. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6228 6. Remove the differential side gears and the differential side gear thrust washers. Assembly 1. Lubricate the differential side gear thrust washers and the differential side gear journals with Motorcraft SAE 75W90 4x4 Axle Lubricant XY-75W90-QL or equivalent meeting Ford specification WSP-M2C201-A. 2. Position the differential side gear thrust washers on the differential side gears. 3. Position the differential side gears. 4. Lubricate the differential pinion thrust washers and the differential pinion gears and assemble them. - Use Motorcraft SAE 75W90 4x4 Axle Lubricant XY-75W90-QL or equivalent meeting Ford specification WSP-M2C201-A. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6229 5. Engage the differential pinion gears opposite the differential side gears. 6. Rotate the differential pinion gears to align with the differential pinion shaft bore. 7. Insert the differential pinion shaft. 8. NOTE: If a new pinion shaft bolt is unavailable, coat the threads with Thread lock and Sealer E0AZ-19554-AA or equivalent meeting Ford specifications WSK-M2G315-A5 and ESE-M4G204-A2 prior to installation. Install a new differential pinion shaft bolt, Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6230 9. CAUTION: Do not press on the bearing. Install the ring gear. 1 Position three bolts to align the holes in the ring gear and the differential case. 2 Using a suitable press, install the ring gear. 10. Install the remaining bolts. Conventional Special Tools Disassembly 1. Remove the differential case. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6231 2. Remove the 10 ring gear bolts. 3. CAUTION: Care should be taken not to damage the bolt hole threads. Insert a punch in the bolt holes and drive the ring gear off. 4. NOTE: The speed sensor ring cannot be reused once removed. Remove the speed sensor ring if required. 5. Using the special tools, remove the differential bearing. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6232 6. Remove the differential pinion shaft lock bolt. 7. Remove the differential pinion shaft. 8. Rotate and remove the differential pinion gear and differential pinion thrust washer. 9. Remove the differential side gear and the differential pinion thrust washer. Assembly Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6233 1. Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B meeting Ford specification WSL-M2C192-A to lubricate the differential side gear thrust washer and the differential side gear journals. Position the differential side gear thrust washer on the differential side gear. 2. Position the differential side gear. 3. Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A to lubricate the differential side gear thrust washer and the differential pinion gear and assemble. 4. Engage the differential pinion gear opposite the differential side gear. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6234 5. Rotate the differential pinion gear to align with the differential pinion shaft bore. 6. Insert the differential pinion shaft. - Align the hole in the differential pinion shaft with the hole in the differential case. 7. NOTE: If a new pinion shaft lock bolt is unavailable, coat the threads with Thread lock and Sealer E0AZ-19554-AA or equivalent meeting Ford specifications WSK-M2G315-A5 and ESE-M4G204-A2 prior to installation. Install a new differential pinion shaft lock bolt and tighten finger-tight. 8. Using the special tool, install the new differential bearings on the differential case. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6235 9. CAUTION: Make sure that the notches on the case flange and the anti-lock speed sensor ring are aligned. Press the new anti-lock speed sensor ring and the ring gear on the differential case. 10. Install the ring gear bolts. - Apply Stud and Bearing Mount E0AZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to ring gear bolts. 11. Install the differential case. Traction-Lok Special Tools, Part 1 Of 3 Special Tool Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6236 Special Tools Disassembly 1. Remove the differential case. 2. Remove the 10 ring gear bolts. 3. CAUTION: Care should be taken not to damage the bolt hole threads. Insert a punch in the bolt holes and drive the ring gear off. 4. NOTE: The anti-lock speed sensor ring cannot be reused once removed. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6237 Remove the speed sensor ring, if required. 5. Using the special tools, remove the differential bearing. - Repeat for the other side. 6. Remove the differential pinion shaft lock bolt and remove the differential pinion shaft. 7. WARNING: Due to the spring tension, care must be used when removing the differential clutch spring. Remove the differential clutch spring. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6238 8. Remove the differential gears. 1 Remove the two differential pinion gears. 2 Remove the two differential side gears. 3 Remove the two differential pinion thrust washers. 9. CAUTION: Keep the differential clutch packs in order. Do not mix them. They must be reassembled in the same sequence. Remove the differential clutch packs and differential side gears and tag them "right" and "left" with the shim. Clean and inspect the remaining parts of the differential case for wear or damage and replace parts as necessary. 10. CAUTION: Do not use acids or solvents when cleaning the differential clutch pack. Wipe components with a clean, lint-free cloth only. Clean and inspect the differential clutch packs for wear and replace parts as necessary. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6239 Assembly 1. CAUTION: 118 ml (4 oz) of the specified Ford Friction Modifier must be used in the axle. Prelubricate each steel clutch plate and soak all friction plates with additive Ford Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A for at least 15 minutes. 2. CAUTION: Do not mix the differential clutch packs or shims from one side with the other. Assemble the differential clutch packs (without the shims) on the respective differential side gears. 3. CAUTION: Make sure the correct mandrel is used with the special tool. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6240 Place the base portion of the special tool in a vise. Install the differential clutch pack and differential side gear (without the shim) on the gauge. 4. Position the special tool hand-tight on top of the differential clutch pack. 5. Install the special tool over the disc and differential clutch pack. 6. Install the nut of the gauge over the top and base stud. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6241 7. NOTE: Selective shims shown are available as part of the Clutch Pack Replacement Kit F5AZ-4947-BA. Use the Feeler Gauge and select the thickest blade that will enter between the tool and the differential clutch pack. The reading will be the thickness of the new clutch shim. 8. Remove the special tool from the clutch pack and side gear assembly. 9. Install shims on the clutch pack and side gear assembly. 10. Install the differential side gear in the differential case. 11. Install the differential pinion gears with differential pinion thrust washers in the differential case. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6242 12. Install the differential clutch spring, using a soft-faced hammer. 13. Install the differential pinion shaft and install a new differential pinion shaft lock bolt finger-tight. 14. Use the special tool to install the differential bearing on the differential case. Repeat for the other side. 15. CAUTION: Make sure that the notches on the case flange and the anti-lock speed sensor ring are aligned. Press the new anti-lock speed sensor ring and the ring gear on the differential case. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6243 16. Install the ring gear bolts. - Apply Stud and Bearing Mount E0AZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to the ring gear bolts. 17. Check the torque required to rotate one differential side gear. - Mount the differential case and special tool in a vise. - The initial minimum break-away torque, if original clutch plates are used, must be within specification. The minimum rotating torque required to keep the differential side gear turning with new clutch plates may vary. 18. Install the differential case. Removal and Installation Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6244 Special Tools Removal 1. Remove the axle shafts. 2. Wipe the lubricant from the internal working parts, and visually inspect the parts for wear or damage. 3. Rotate the differential case to see if there is any roughness which would indicate damaged bearings or gears. 4. NOTE: There is a space between the anti-lock speed sensor ring and the ring gear for measuring ring gear back face runout. Position the special tool and inspect ring gear backlash and ring gear back face runout. 5. CAUTION: Mark the position of the bearing caps as arrows may not be visible. The bearing caps must be installed in their identical Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6245 locations and positions. Loosen the differential case. 1 Remove the bearing cap bolts. 2 Remove the bearing caps. 6. To simplify the installation, fabricate two differential case retaining straps from metal stock as shown. 7. WARNING: Be careful not to allow the differential case to fall. CAUTION: Place a wood block between the pry bar and the rear axle housing to protect the machined surface from damage. Use the pry bar and the wood block to remove the differential case from the rear axle housing. 8. Remove the ring gear bolts. 9. CAUTION: Care should be taken not to damage the ring gear bolt hole thread. NOTE: The anti-lock speed sensor ring cannot be reused once removed. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6246 Insert a punch in the bolt holes. Drive off the ring gear and, if necessary, the anti-lock speed sensor ring. 10. Install the differential case. 1 Position the differential case assembly, including bearing cups and shims, in the carrier. 2 Install the differential bearing caps. 3 Install the differential bearing cap bolts. 11. Position the special tool. 1 Rotate the differential case to make sure the differential bearings are correctly seated. 2 Position the special tool. 12. NOTE: If runout is less than specification, install a new ring gear and pinion. If runout exceeds specification, the ring gear is true and the concern is due to either a damaged differential case or differential bearings. Inspect the differential bearings. If the differential bearings are not damaged, install both the differential case and the differential bearings new. Measure the differential case runout without the ring gear. 1 Rotate the differential case. 2 Check and note the differential case runout. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6247 13. Remove the differential case from the rear axle housing, and remove the differential bearings using the special tools. 14. Using the special tool, install the new differential bearings on the differential case. 15. Measure the differential case runout without the ring gear. - Check the case runout again with the new differential bearings. If the runout is now within the specification shown, use the new differential bearings for assembly. If the runout is still excessive, the differential case is damaged and must be installed new. Installation 1. CAUTION: Make sure that the notches on the case flange and the anti-lock speed sensor ring are aligned. Press the ring gear and, if removed, a new anti-lock speed sensor on the differential case. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6248 2. Install the ring gear bolts. - Apply Stud and Bearing Mount E0AZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to the ring gear bolts. 3. With pinion depth set and the pinion installed, place the differential case in the rear axle housing. 4. Install a shim on the left side. 5. CAUTION: Mark the position of the bearing caps as arrows may not be visible. The bearing caps must be installed in their identical locations and positions. NOTE: Apply pressure toward the left side to make sure the left bearing cap is seated. Install the left bearing cap, and loosely install the bearing cap bolts. 6. Install progressively larger shims on the right side until the largest shim selected can be assembled by hand. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6249 7. Install the right side bearing cap, and tighten the bolts. 8. Rotate the differential case to make sure it rotates freely. 9. Using the special tool, measure ring gear backlash. - If the backlash is within specification, go to Step 15. The specification shown in the illustration is the total allowable range. - If a zero backlash condition occurs, go to Step 10. - If the backlash is not within specification, go to Step 11. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6250 10. If a zero backlash condition occurs, add a 0.50 mm (0.020 inch) shim to the RH side and subtract 0.50 min (0.020 inch) from the LH side to allow backlash indication. Check backlash. Repeat Step 9. 11. To increase or decrease backlash, remove the bearing caps, and install a thicker shim and a thinner shim as shown. - If backlash is not within specification, correct by increasing the thickness of one differential bearing shim and decreasing the thickness on the other differential bearing shim by the same amount. 12. Install the bearing caps and bearing cap bolts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6251 13. Rotate the differential several times to make sure the differential bearings are correctly seated. 14. Using the special tool check the backlash. - If backlash is within specification, go to Step 15. If not, repeat Step 9. - The specification shown in the illustration is the total allowable range. 15. Remove the bearing caps and bolts. - To establish differential bearing preload, increase both left and right shim sizes by the specification shown in the illustration. - Using a special tool, ensure the differential bearing shims are fully seated and the assembly turns freely. 16. Install the bearing caps and bearing cap bolts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6252 17. Using the special tool, verify the backlash. - The specification shown in the illustration is the total allowable range. 18. Install the axle shafts. Conventional Special Tools Disassembly 1. Remove the differential case. 2. Remove the ring gear bolts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6253 3. Insert a punch in the bolt holes and drive the ring gear off. 4. NOTE: The anti-lock speed sensor ring cannot be reused once removed. Remove the anti-lock speed sensor ring. 5. If required, remove the differential bearings with the special tools. 6. Remove the differential pinion shaft lock bolt and the differential pinion shaft. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6254 7. Rotate and remove the differential pinion gears and differential pinion thrust washers. 8. Remove the differential side gears and the differential side gear thrust washers. Assembly 1. Position the differential side gear thrust washers on the differential side gears. - Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A to lubricate the differential side gear thrust washers and the differential side gear journals. 2. Position the differential side gears. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6255 3. Assemble the differential pinion thrust washers and the differential pinion gears. - Lubricate with Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 4. Engage the differential pinion gears opposite the differential side gears. 5. Install the differential bearings, using the special tool. 6. Rotate the differential pinion gears to align the differential pinion shaft bore. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6256 7. Insert the differential pinion shaft, and install a new differential pinion shaft lock bolt finger-tight. 8. CAUTION: Make sure that the notches on the case flange and the anti-lock speed sensor ring are aligned. Press the new anti-lock speed sensor ring and the ring gear on the differential case. 9. Install the ring gear bolts and tighten. - Apply Stud and Bearing Mount E0AZ-19554-BA or equivalent meeting Ford specification WSK-M2G349-A1 to the ring gear bolts. 10. Replace the differential bearings, if removed. 11. Install the differential case. Traction-Lok Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6257 Special Tools Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6258 Disassembly 1. Remove the differential case. 2. NOTE: The differential bearings need not be removed to overhaul the Ford limited slip differential. If bearing removal is required, use the special tool 205-DO72 (D97L-4221-A) for differential case bearings. NOTE: The anti-lock speed sensor ring cannot be reused once removed. Remove the differential pinion shaft lock bolt and remove the differential pinion shaft. If required, remove the ring gear and anti-lock speed sensor ring. 3. Install the special tool in a suitable vise. 4. Install the differential case on the tool. 5. NOTE: Apply a small amount of grease to the centering hole of the special tool 205-D019 (D80L-630-8). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6259 Install the special tool in the bottom side gear bore. 6. Install the nut in the upper differential side gear. Hold the nut in position while installing the hex screw. Tighten the hex-head screw until contact is made with special tool 205-D019 (D80L-630-8). 7. NOTE: The dowel bar is used to keep the nut from turning when the forcing screw is tightened. Insert a suitable dowel bar in the hole of the nut. Tighten the forcing screw to force the differential side gear away from the differential pinion gears. 8. WARNING: Keep fingers/hands away from pinion gears when rotating the differential case with the differential rotating tool. NOTE: Differential pinion thrust washers cannot be removed independently of the differential pinion gears and so must be removed simultaneously with the differential pinion gears. Insert special tool in the pinion shaft bore, and turn the differential case to "walk" the differential pinion gears and differential pinion thrust Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6260 washers out to the differential case windows. 9. Remove the differential pinion gears and differential pinion thrust washers. 10. Remove the differential side gears and differential clutch packs, and tag them RIGHT and LEFT with the shim. 11. CAUTION: When separating the clutch plates and clutch discs, note the sequence in which they are disassembled. They must be reassembled in the same sequence. CAUTION: Do not use acids or solvents when cleaning the differential clutch pack. Wipe components with a clean, lint-free cloth only. Separate the differential clutch discs and clutch plates for cleaning and inspection. Assembly Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6261 1. Prelubricate each steel clutch plate and soak all friction plates with 118 ml (4 ounces) Additive Friction Modifier C8AZ-1913546-A or equivalent meeting Ford specification EST-M2C118-A for at least 15 minutes. 2. NOTE: Do not mix the differential clutch packs or shims from one side with the other. NOTE: The Belleville spring is a dished plate. Assemble the differential clutch packs (without the shims and Belleville springs) on the respective differential side gears. 3. Clamp the bolt head of the special tool in a vise. Install the differential clutch pack and the differential side gear (without the shim or the Belleville spring) on the gauge. 4. Position the special tool on top of the differential clutch pack. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6262 5. Install the special tool over the disc and differential clutch pack. 6. Install the nut over the top and base stud. 7. Use the special tool 303-DO27 (D81L-4201-A) and select the thickest blade that will enter between the tool and the differential clutch pack. Subtract 0.010 inch from the reading to obtain the thickness of the new clutch shim. A maximum of two shims can be used. Select the correct shim(s) size and remove the special tool 205-135 (T80P-4946-A). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6263 8. Place the shim and Belleville spring on the differential clutch pack. - The dished or concave side of the Belleville spring must face up and against the thrust face of the differential case. 9. Insert the differential clutch packs with shims and Belleville springs and differential side gears into the differential case. - Hold the upper clutch pack and side gear assembly in place to prevent it from falling out of the differential case. 10. NOTE: Apply a small amount of grease to the step plate bore. NOTE: If necessary, insert the dowel bar in the nut bore to keep the nut from turning as the hex screw is tightened. Assemble the special tool to the differential case. 1 Position the special tool in the bottom side gear bore. 2 Position the special tool in the top side gear bore and hold it in place. 3 Install the special tool and tighten it two turns after it contacts the bottom step plate. 11. NOTE: Prelubricate both sides of the differential pinion thrust washers with Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6264 equivalent meeting Ford specification WSL-M2C192-A. NOTE: Make sure the differential pinion gears are 180° apart so they will align correctly with the pinion shaft bore. Position the differential pinion gears and differential pinion thrust washers in the window of the differential case so they mesh with the differential side gear teeth. 12. WARNING: Keep fingers/hands away from pinion gears when rotating the differential case with the differential rotating too). NOTE: It will probably be necessary to loosen or tighten the forcing screw to allow the differential pinion gears and differential side gears to rotate. Insert the special tool into the pinion shaft bore, and turn the differential case. This will cause the differential pinion gears to engage the differential side gears and "walk" into the differential case. Rotate the differential case until the pinion mating shaft holes are lined up exactly with the holes in the differential pinion gears. 13. Loosen the forcing screw, and remove the step plate and nut from the side gear bores. Install a new differential pinion shaft in the differential case. - Install the differential pinion shaft lock bolt finger-tight. 14. Install new differential bearings, if removed. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Front Differential > Page 6265 15. Check the torque required to rotate one differential side gear. - Install the special tools with the 1/2-inch drive hole as shown. - The initial break-away torque, if original clutch plates are used, must be within specification. The rotating torque required to keep the differential side gear turning with new clutch plates may vary. 16. CAUTION: Make sure that the notches on the case flange and the anti-lock speed sensor ring are aligned. Install the ring gear and, if removed, a new anti-lock speed sensor ring on the differential case and tighten the retaining bolts. 17. Install the differential case. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Front Front Axle Fluid Capacity Capacity ............................................................................................................................................... ............................................................ 3.5 - 3.7 Pints 3/8 inch below the bottom of fill hole. Rear Differential Fluid Capacity Capacity ............................................................................................................................................... .................................................................. 2.6 - 2.7L Fill no higher than 1/4 to 9/16 inch below fill plug. For complete fill of 8.8 and 9.75 Traction-Lok axles add 4 oz. of friction modifier C8AZ-19B956-A. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 6270 Fluid - Differential: Fluid Type Specifications Front Axle ............................................................................................................................................ ............................................................. SAE 75W-90 Rear Axle ............................................................................................................................................. .......................................... SAE 75W-140 Synthetic Note: The rear axle is filled with a synthetic axle lubricant and is considered lubricated for life. These lubricants do not need to be checked nor changed unless a leak is suspected, service is required, or the axle has been submerged in water. The axle lubricant should be changed any time the axle has been submerged in water. Add 4 ounces of friction modifier additive C8AZ-19B546-A, Ford specification EST-M2C118A for complete refill of Traction-Lok axles. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Page 6271 Fluid - Differential: Service Precautions DO NOT over fill differential beyond normal fluid level. Fluid foaming and damage may occur. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear Pinion Flange: Service and Repair 8.8 Inch Ring Gear Front Special Tools Removal WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. CAUTION: This operation disturbs the pinion bearing preload. Carefully reset the preload during assembly. 1. Raise and support the vehicle. 2. Remove the front differential support. 1 Remove the nut and bolt. 2 Remove the nuts and bolts. 3 Remove the front differential support. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6276 3. Index-mark the front driveshaft to the axle universal joint flange. 4. CAUTION: Do not allow the driveshaft to hang unsupported. Disconnect and support the front driveshaft. 1 Remove the four bolts. 2 Carefully disconnect and support the front driveshaft. 5. Using a Nm (inch/pound) torque wrench, measure the torque necessary to maintain pinion rotation. Record the measurement for reference during installation. 6. Index-mark the axle universal joint flange to the pinion stem. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6277 7. Install the special tool, and loosen, but do not remove the pinion nut. CAUTION: Before proceeding, place a drain pan under the differential carrier. 8. With the pinion nut still engaged by a few threads, use the special tool to separate the axle universal joint flange from the pinion gear. 9. Inspect the axle universal joint flange for removal damage, burrs, bearing cone contact area damage, and inspect the nut counterbore and the seal contact surface for nicks. Install a new flange if necessary. 10. Check the pinion stem splines for burrs. If burrs are evident, remove them with a fine crocus cloth. Working in a rotating motion, wipe the pinion clean. Installation 1. Lubricate the axle universal joint flange splines and the pinion seal. - Use Motorcraft SAE 75W90 4x4 Axle Lubricant XY-75W90-QL or equivalent meeting Ford specification WSP-M2C201-A. 2. CAUTION: Never install the axle universal joint flange with a hammer or power tools. NOTE: Disregard the scribe marks if installing a new flange. Align the index-marks and position the axle universal joint flange on the pinion shaft. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6278 3. NOTE: Rotate the pinion gear occasionally to make sure the pinion bearings seat correctly. Using the special tool, install the axle universal joint flange. 4. CAUTION: Do not loosen the pinion nut to reduce preload under any circumstance. If it is necessary to reduce preload, install a new drive pinion collapsible spacer and pinion nut. Install the special tool, and tighten the pinion nut. Rotate the pinion gear occasionally to make sure the pinion bearings are seating correctly. Take frequent pinion bearing torque preload readings by rotating the pinion gear with a Nm (inch/pound) torque wrench. - If the preload recorded prior to disassembly is lower than the specification for used bearings, then tighten the pinion nut to the specification. If the preload recorded prior to disassembly is higher than the specification for used bearings, then tighten the pinion nut to the original reading as recorded. 5. Align the index-marks then attach the front driveshaft. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6279 6. Install the front differential support. 1 Position the differential support. 2 Install the nuts and bolts. 3 Install the nuts and bolts. 7. Inspect and, if necessary, fill the differential. - Use Motorcraft SAE 75W90 4x4 Axle Lubricant XY-75W90-QL or equivalent meeting Ford specification WSP-M2C201-A. 8. Lower the vehicle. 9. If equipped with air suspension, reactivate the system by turning on the air suspension switch. Rear Special Tools Removal 1. NOTE: The rear wheels and brake drums must be removed to prevent brake drag during drive pinion bearing preload adjustment. Remove the rear brake drums. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6280 2. Mark the driveshaft flange and pinion flange for correct alignment during installation. 3. Remove the four driveshaft bolts and disconnect the driveshaft. Wire the driveshaft out of the way. 4. Install an inch-pound torque wrench on the pinion nut and record the torque required to maintain rotation of the pinion through several revolutions. 5. CAUTION: After removal of the pinion nut, discard it. A new nut must be used for installation. Use the special tool to hold the pinion flange while removing the pinion nut. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6281 6. Mark the pinion flange in relation to the drive pinion stem to ensure proper alignment during installation. 7. Use the special tool to remove the pinion flange. Installation 1. Lubricate the pinion flange splines. - Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 2. NOTE: Disregard the scribe marks if a new pinion flange is being installed. Align the pinion flange with the drive pinion shaft. 3. With the drive pinion in place in the rear axle housing, install the pinion flange using the special tool. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6282 4. Position the new pinion nut. 5. CAUTION: Under no circumstances is the pinion nut to be backed off to reduce preload. If reduced preload is required, a new collapsible spacer and pinion nut must be installed. Using the special tool hold the pinion flange, tighten the pinion nut. Rotate the pinion occasionally to make sure the cone and roller bearings are seating correctly. - Install a Nm (inch-pound) torque wrench on the pinion nut. - Rotating the pinion through several revolutions, take frequent cone and roller bearing torque preload readings until the original recorded preload reading is obtained. - If the original recorded preload is lower than specifications, tighten to the appropriate specifications for used bearings. If the preload is higher than specification, tighten the nut to the original reading as recorded. 6. Position the rear driveshaft and align the marks on the pinion flange. 7. Install the four driveshaft pinion flange bolts. 8. Install the rear brake drums. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6283 Pinion Flange: Service and Repair 9.75 Inch Ring Gear Special Tools Removal 1. NOTE: The rear wheels and brake drums must be removed to prevent brake drag during drive pinion bearing preload adjustment. Remove the rear brake drums. 2. Mark the driveshaft flange and pinion flange for correct alignment during installation. 3. Remove the four driveshaft bolts, and disconnect the driveshaft. Wire the driveshaft out of the way. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6284 4. Install a torque wrench on the pinion nut and record the torque required to maintain rotation of the pinion through several revolutions. 5. CAUTION: After removal of the pinion nut, discard it. A new nut must be used for installation. Use a pinion flange holding tool to hold the pinion flange while removing the pinion nut. 6. Mark the pinion flange in relation to the drive pinion stem to ensure correct alignment during installation. 7. Using the special tools, remove the pinion flange. Installation 1. Lubricate the pinion flange splines. - Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6285 2. NOTE: Disregard the scribe marks if a new pinion flange is being installed. Align the pinion flange with the drive pinion shaft. 3. With the drive pinion in place in the axle housing, install the pinion flange using the special tool. 4. Position the new pinion nut. 5. CAUTION: Under no circumstances is the pinion nut to be backed off to reduce preloads. If reduced preload is required, a new collapsible spacer and pinion nut must be installed. Using a suitable pinion flange holding tool to hold the pinion flange, tighten the pinion nut. Rotate the pinion occasionally to make sure the cone and roller bearings are seating correctly. - Install a Nm (inch-pound) torque wrench on the pinion nut. - Rotating the pinion through several revolutions, take frequent cone and roller bearing torque preload readings until the original recorded preload reading is obtained. - If the original recorded preload is lower than specifications, tighten to the appropriate specification for used bearings. If the preload is higher Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6286 than specification, tighten the nut to the original reading as recorded. 6. Position the driveshaft and align the marks on the pinion flange. 7. Install the four driveshaft bolts. 8. Install the brake drums. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Technical Service Bulletins > Customer Interest for Pinion Gear: > 99-14-3 > Jul > 99 > Front Differential Moaning Noise In 2WD Mode Pinion Gear: Customer Interest Front Differential - Moaning Noise In 2WD Mode Article No. 99-14-3 07/12/99 ^ NOISE - "MOANING" FROM FRONT DIFFERENTIAL WHILE IN 2-WHEEL DRIVE - VEHICLES BUILT THROUGH 4/15/1999 ^ AXLE - "MOANING" NOISE FROM FRONT DIFFERENTIAL WHILE IN 2-WHEEL DRIVE VEHICLES BUILT THROUGH 4/15/1999 FORD: 1997-1999 EXPEDITION, F-150, F-250 LD LINCOLN: 1998-1999 NAVIGATOR ISSUE Some 4X4 vehicles built with center disconnect front axles may exhibit a "moaning" noise from the front differential while operating in 4X2 mode. The noise goes away when operating in 4X4 mode. This may be caused by the front differential side gears. ACTION Replace the front differential side gears with revised gears and replace the front differential pinion gears with revised gears. Refer to the following text for details. For vehicles that exhibit a front differential moan in 4X2 mode that goes away in 4X4 mode, replace both front axle side gears and both front axle pinion gears. Replace any worn or damaged pinion thrust washers and side gear washers. Refer to Section 205-03 of the appropriate model/year Workshop Manual for removal and installation procedures. PART NUMBER PART NAME XL3Z-4236-M Side Gears (2 Per Box) XL3Z-4215-M Pinion Gears (2 Per Box) DOAZ-4230-B Pinion Thrust washer C90Z-4228-B Side Gear washer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991403A Replace Axle Side Gears 1.4 Hrs. And Pinion Gears DEALER CODING CONDITION BASIC PART NO. CODE 4235 42 OASIS CODES: 509000, 597997, 702100 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pinion Gear: > 99-14-3 > Jul > 99 > Front Differential - Moaning Noise In 2WD Mode Pinion Gear: All Technical Service Bulletins Front Differential - Moaning Noise In 2WD Mode Article No. 99-14-3 07/12/99 ^ NOISE - "MOANING" FROM FRONT DIFFERENTIAL WHILE IN 2-WHEEL DRIVE - VEHICLES BUILT THROUGH 4/15/1999 ^ AXLE - "MOANING" NOISE FROM FRONT DIFFERENTIAL WHILE IN 2-WHEEL DRIVE VEHICLES BUILT THROUGH 4/15/1999 FORD: 1997-1999 EXPEDITION, F-150, F-250 LD LINCOLN: 1998-1999 NAVIGATOR ISSUE Some 4X4 vehicles built with center disconnect front axles may exhibit a "moaning" noise from the front differential while operating in 4X2 mode. The noise goes away when operating in 4X4 mode. This may be caused by the front differential side gears. ACTION Replace the front differential side gears with revised gears and replace the front differential pinion gears with revised gears. Refer to the following text for details. For vehicles that exhibit a front differential moan in 4X2 mode that goes away in 4X4 mode, replace both front axle side gears and both front axle pinion gears. Replace any worn or damaged pinion thrust washers and side gear washers. Refer to Section 205-03 of the appropriate model/year Workshop Manual for removal and installation procedures. PART NUMBER PART NAME XL3Z-4236-M Side Gears (2 Per Box) XL3Z-4215-M Pinion Gears (2 Per Box) DOAZ-4230-B Pinion Thrust washer C90Z-4228-B Side Gear washer OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991403A Replace Axle Side Gears 1.4 Hrs. And Pinion Gears DEALER CODING CONDITION BASIC PART NO. CODE 4235 42 OASIS CODES: 509000, 597997, 702100 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear Pinion Gear: Service and Repair 8.8 Inch Ring Gear Special Tools Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6302 Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6303 Removal 1. Remove the differential case, 2. Mark the driveshaft flange and the pinion flange for correct alignment during installation. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6304 3. Remove the four driveshaft bolts and disconnect the driveshaft. 4. Install an Nm (inch-pound) torque wrench on the pinion nut and record the torque required to maintain rotation of the pinion through several revolutions. 5. Remove the pinion flange and pinion nut. 6. Install the special tool and, with a soft-faced hammer, drive the pinion assembly out of the front bearing cone and remove it through the rear of the housing. Remove the rear axle drive pinion seal. - Remove the rear axle drive pinion shaft oil slinger. 7. NOTE: Remove the collapsible spacer and discard it. Using the special tool, remove the pinion bearing. 8. NOTE: Do not remove the pinion bearing cups from the housing unless the cups are damaged. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6305 Remove the outer differential bearing cup with the special tools. 9. Remove the inner differential bearing cup with the special tools. Installation 1. Position the special tools and the inner and outer bearing cups in their respective bores. 1 After placing the inner and outer bearing cups in their bores, place the special tool (inner) on the inner pinion bearing cup. 2 Place the special tool (outer) on the outer pinion bearing cup. 3 Install the special tool. 2. Tighten the special tool to seat the pinion bearing cups into their bores. 3. NOTE: Steps 3 and 4 are an alternate method of performing Steps 1 and 2. Drive the outer pinion bearing cup into the rear axle housing using the special tools. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6306 4. Drive the inner pinion bearing cup into the axle housing using the special tools. 5. CAUTION: Whenever the cups are replaced, the pinion bearings must also be replaced. NOTE: If a feeler gauge can be inserted between a cup and the bottom of its bore at any point around the cup, the cup is not correctly seated. Make sure the cups are correctly seated in their bores. 6. NOTE: Apply only a light oil film on the pinion bearings before assembling the tool. Assemble and position the special tool. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6307 7. NOTE: This step duplicates final pinion bearing preload. Tighten the special tool to the specification shown. 8. NOTE: The special tool must be offset to obtain an accurate reading. Rotate the special tool several half-turns to ensure proper seating of the pinion bearings and position the special tool. 9. Install the special tool. 1 Position the special tool. 2 Install the differential side bearing caps. 3 Install the four differential side bearing cap bolts. 10. NOTE: Drive pinion bearing adjustment shims must be flat and clean. NOTE: A slight drag should be felt for correct shim selection. Do not attempt to force the pinion shim between the Gauge Block and the Gauge Tube. This will minimize selection of a pinion shim thicker than required, which results in a deep tooth contact in final assembly of integral rear axle assemblies. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6308 Use a drive pinion bearing adjustment shim as a gauge for shim selection. After the correct shim thickness has been determined, remove the Gauge Tube. 11. Using a press and the special tool, press the pinion bearing and pinion shim until it is firmly seated on the pinion. 12. Place a new drive pinion collapsible spacer on the pinion shaft against the pinion stem shoulder. 13. From inside the rear axle housing, install the drive pinion assembly (drive pinion, shims, rear bearing cone and roller, and drive pinion collapsible spacer) into the rear axle bore. 14. CAUTION: Installation without the correct tool can result in early seal failure. If the rear axle drive pinion seal becomes cocked during installation, remove it and install a new one. Install a new rear axle drive pinion seal. 1 Install the front pinion bearing cone and roller. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6309 2 Install the rear axle drive pinion shaft oil slinger in the rear axle housing. 3 Install the rear axle drive pinion seal on the special tool. 15. NOTE: Coat the lips of the rear axle drive pinion seal with Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Place the special tool in the rear axle drive pinion seal bore, and drive the rear axle drive pinion seal into place. 16. Lubricate the pinion flange splines. - Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 17. NOTE: Disregard the scribe marks if a new pinion flange is being installed. Align the pinion flange with the drive pinion shaft. 18. With the drive pinion in place in the rear axle housing, install the pinion flange using the special tool. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6310 19. Position the new pinion nut. 20. CAUTION: Under no circumstances is the pinion nut to be backed off to reduce preload. If reduced preload is required, a new collapsible spacer and pinion nut must be installed. Using the special tool to hold the pinion flange, tighten the pinion nut. Rotate the pinion occasionally to make sure the cone and roller bearings are seating correctly. - Install a Nm (inch-pound) torque wrench on the pinion nut. - Rotating the pinion through several revolutions, take frequent cone and roller bearing torque preload readings until the original recorded preload reading it obtained. 21. Install the differential case in the rear axle differential. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6311 Pinion Gear: Service and Repair 9.75 Inch Ring Gear Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6312 Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6313 Special Tools Special Tools Removal 1. Remove differential case. 2. Mark the driveshaft flange and the pinion flange for correct alignment during installation. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6314 3. Remove the four driveshaft bolts, and disconnect the driveshaft. Wire the driveshaft out of the way. 4. Install a Nm (inch-pound) torque wrench on the pinion nut, and record the torque required to maintain rotation of the pinion through several revolutions. 5. Remove the pinion flange and pinion nut. 6. Remove the rear axle drive pinion seal. 7. Remove the rear axle drive pinion shaft oil slinger. 8. Install the special tool and, with a soft-faced hammer, drive the pinion out of the outer pinion bearing and remove the drive pinion through the rear of the housing. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6315 9. Remove the collapsible spacer and discard it. 10. Using the special tool, remove the pinion bearing cone and roller assembly. 11. NOTE: Do not remove the pinion bearing cups from the carrier casting unless the cups are damaged. Remove the outer differential bearing cup with the special tools. 12. Remove the inner differential bearing cup with the special tools. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6316 1. Position the special tools and the inner and outer bearing cups in their respective bores. 1 After placing the inner and outer bearing cups in their bores, place the special tool on the inner pinion bearing cup. 2 Place the special tool on the outer pinion bearing cup. 3 Install the special tools. 2. Tighten the special tool to seat the pinion bearing cups into their bores. 3. NOTE: Steps 3 and 4 are on alternate method of performing Steps 1 and 2. Drive the outer pinion bearing cup into the rear axle housing, using the special tools. 4. Drive the inner pinion bearing cup into the rear axle housing, using the special tools. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6317 5. CAUTION: Whenever the cups are installed new, the differential pinion bearings must also be installed new. NOTE: If a feeler gauge of the specification shown in the illustration can be inserted between a cup and the bottom of its bore at any point around the cup, the cup is not correctly seated. Make sure the cups are correctly seated in their bores. 6. NOTE: Apply only a light oil film on the pinion bearings before assembling the tool. Assemble and position the Pinion Depth Gauge. 7. Tighten the special tool. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6318 8. NOTE: The special tool must be offset to obtain an accurate reading. Rotate the special tool several half-turns to ensure proper seating of the pinion bearings, and position the special tool. 9. Install the special tool. 1 Position the special tool. 2 Install the differential side bearing caps. 3 Install the differential side bearing cap bolts. 10. NOTE: Drive pinion bearing adjustment shims must be flat and clean. NOTE: A slight drag should be felt for correct shim selection. Do not attempt to force the pinion shim between the Gauge Block and the Gauge Tube. This will minimize selection of a pinion shim thicker than required, which results in a deep tooth contact in the final assembly of integral rear axle assemblies. Use a drive pinion bearing adjustment shim as a gauge for shim selection. After the correct shim thickness has been determined, remove the special tools. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6319 11. Using a press and the special tool, press the pinion bearing and pinion shim until they are firmly seated on the pinion. 12. Place a new drive pinion collapsible spacer on the pinion shaft against the pinion stem shoulder. 13. Install the drive pinion in the drive pinion carrier bore from inside the rear axle housing. Seat the drive pinion with a plastic hammer. 14. CAUTION: Installation without the correct tool can result in early seal failure. If the rear axle drive pinion seal becomes cocked during installation, remove it and install a new one. Install a new rear axle drive pinion seal. 1 Install the outer pinion bearing cone and roller. 2 Install the rear axle drive pinion shaft oil slinger in the rear axle housing. 3 Install the rear axle drive pinion seal on the special tool. 15. NOTE: Coat the lips of the rear axle drive pinion seal with Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Place the special tool in the pinion seal bore and drive the rear axle drive pinion seal into place. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6320 16. Lubricate the pinion flange splines. - Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 17. NOTE: Disregard the scribe marks if a new pinion flange is being installed. Align the pinion flange with the drive pinion shaft. 18. With the drive pinion in place in the axle housing, install the pinion flange using the special tool. 19. Position the new pinion nut. 20. CAUTION: Under no circumstances is the pinion nut to be backed off to reduce preload. If reduced preload is required, a new drive pinion collapsible spacer and pinion nut must be installed. Using a suitable pinion flange holding tool to hold the pinion flange, tighten the pinion nut. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > 8.8 Inch Ring Gear > Page 6321 - Rotate the pinion occasionally to make sure the cone and roller bearings are seating correctly. - Install a Nm (inch-pound) torque wrench on the pinion nut. - Rotating the pinion through several revolutions, take frequent cone and roller bearing torque preload readings until the original recorded preload reading is obtained. - If the original recorded preload is lower than specifications, tighten to the appropriate specifications for used bearings. If the preload is higher than specification, tighten the nut to the original reading as recorded. 21. Install the differential case. 22. Install the driveshaft. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > 8.8 Inch Ring Gear Seals and Gaskets: Service and Repair 8.8 Inch Ring Gear Front Special Tools Removal 1. Remove the front axle universal joint flange. 2. CAUTION: Do not damage the front axle housing. Remove the pinion seal. Installation 1. Clean the pinion seal bore, and use the Pinion Seal Replacer to install the pinion seal. 2. Install the front axle universal joint flange. Rear Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > 8.8 Inch Ring Gear > Page 6326 Special Tools Removal 1. Remove the pinion flange. 2. Force up on the metal flange of the rear axle drive pinion seal. Install gripping pliers and strike with a hammer until the rear axle pinion seal is removed. Installation 1. Lubricate the new rear axle drive pinion seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 2. CAUTION: If the rear axle drive pinion seal becomes misaligned during installation, remove the rear axle drive pinion seal and install a new seal. Use the special tool to install the rear axle drive pinion seal. 3. Install the pinion flange. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System Information > Service and Repair > 8.8 Inch Ring Gear > Page 6327 Seals and Gaskets: Service and Repair 9.75 Inch Ring Gear Special Tools Removal 1. Remove the pinion flange. 2. Force up on the metal flange of the rear axle drive pinion seal. Install gripping pliers and strike with a hammer until the pinion seal is removed. Installation 1. Lubricate the new rear axle drive pinion seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 2. CAUTION: If the rear axle drive pinion seal becomes misaligned during installation, remove the seal and install new. Using the special tool, install the rear axle drive pinion seal. 3. Install the pinion flange. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications Axle Shaft: Specifications Front Wheel Driveshaft and Joint Assembled Length 417.25 mm CV Joint to Boot Spacing 66 mm Front Wheel Halfshaft and Joint Bolts 68-92 Nm Hub Nut 255-345 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 6333 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 6334 Axle Shaft: Diagrams Part 1 Of 2 Part 2 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 6335 Axle Shaft: Description and Operation The halfshaft assembly transmits equal engine torque from the axle to both front wheels. The halfshaft assembly uses a Constant Velocity (CV) joint, at both the inboard and outboard ends, for smooth operation. The CV joints rotate at approximately one-third the speed of a driveshaft and do not normally contribute to any rotational vibration that may occur. The only replaceable components of the halfshaft assembly are: Halfshaft joint boots (inboard and outboard). Replacement kit includes front wheel driveshaft joint boots and clamps, snap rings, retainer ring and grease. - Inboard CV joint (plunge type). - Side shaft. Replacement includes the outboard front wheel halfshaft joint (fixed type), outboard boot and clamps, front wheel excluder seal (assembled on the interconnecting shaft). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front Axle Shaft: Service and Repair Front Removal and Installation Special Tools Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the hub nut. 1 Remove and discard the cotter pin. 2 Remove the retainer. 3 Remove the hub nut. 4. Position the front disc brake caliper aside. 1 Remove the two caliper bolts. 2 Lift the front disc brake caliper off the front disc brake caliper anchor plate and position aside. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front > Page 6338 5. Remove the upper ball joint castle nut. 1 Remove and discard the cotter pin. 2 Remove the castle nut. 6. Using Pitman Arm Puller, separate the front wheel knuckle from the front suspension upper arm. 7. Remove the six front wheel halfshafts and joint bolts. 8. CAUTION: Use caution to avoid damaging the hub seal when removing the front drive halfshaft. Separate the halfshaft assembly from the hub and remove the halfshaft assembly from the vehicle. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front > Page 6339 1. Install the halfshaft, then the six halfshaft bolts. 2. Install the front disc brake caliper. 1 Position the front disc brake caliper. 2 Install the front disc brake caliper bolts. 3. Install the wheel hub nut. 1 Install the hub nut. 2 Install the retainer. 3 Install a new cotter pin. 4. Install the front suspension arm upper ball joint castle nut. 1 Position the front wheel knuckle. 2 Install the upper ball joint castle nut. 3 Install a new cotter pin. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front > Page 6340 5. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. 6. Install the wheel and tire assembly. Disassembly and Assembly Special Tools Disassembly 1. Remove the front wheel driveshaft and joint, please refer to Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/ Axle Shaft/Service and Repair/ See: 2. Slide the two inboard clamp protectors off the boot clamps. 3. CAUTION: Be careful not to damage the front wheel driveshaft joint boot. Remove the two inboard front wheel driveshaft joint boot clamp. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front > Page 6341 4. Slide the inboard front wheel driveshaft joint boot off the inboard CV joint housing. 5. Remove the retaining ring. 6. Remove the inboard CV joint housing. 7. Mark the inner race and the ball cage for assembly. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front > Page 6342 8. Remove the six balls. 9. Remove the snap ring. 10. Remove the inner race and ball cage. 11. Remove the inboard front wheel driveshaft joint boot and the clamp protector. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front > Page 6343 12. Remove the two outboard boot clamps. 1 Remove the outboard clamp protectors. 2 Grip the boot clamps and peel the clamps away from the boot. 13. Remove the outboard front wheel driveshaft joint boot. 14. NOTE: If grease is contaminated, clean and inspect the joint for wear. Replace the outboard CV joint and interconnecting shaft assembly if worn or damaged. Inspect for contaminated grease. Assembly 1. Pack the outboard CV joint with grease. 1 Use High Temp Constant Velocity Joint Grease E43Z-19590-A or equivalent meeting Ford specification ESP-M1C207-A provided in the boot kit. 2 Spread any remaining grease from service kit evenly inside the outboard boot. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front > Page 6344 2. Position the outboard front wheel driveshaft joint boot and outboard boot clamps. 1 Clean the front wheel driveshaft joint boot mounting surface. 2 Position the outboard front wheel driveshaft joint boot in the outboard CV joint grooves and position the boot clamps. 3. NOTE: Tighten the through-bolt until the installer is in the closed position. Use the CV Boot Clamp Installer to install the boot clamps. 4. Install the two outboard clamp protectors. 5. Position the inboard clamp protector and the boot clamp on the halfshaft assembly. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front > Page 6345 6. Position the front wheel inboard drive shaft joint boot. 7. Position the ball cage on the halfshaft assembly with the tapered end toward the front wheel driveshaft joint boot. 8. NOTE: Line up the marks made during disassembly. Position the inner race on the halfshaft assembly with the counterbored end towards the front wheel driveshaft joint boot. 9. Install the snap ring. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front > Page 6346 10. Lubricate and position the six balls. - Use High Temp Constant Velocity Joint Grease E43Z-19590-A provided in the boot kit meeting Ford specification ESP-M1C207-A. 11. Position the clamp protector and the inboard boot clamp on the inboard CV joint housing. 12. Fill the inboard CV joint housing with 235 grams of grease. - Use High Temp, Constant Velocity Joint Grease E43Z-19590A provided in the boot kit meeting Ford specification ESP-M1C207-A. 13. Position the inboard CV joint housing and install the retaining ring. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front > Page 6347 14. Remove any excess grease from the mating surface and position the inboard front wheel driveshaft Joint boot. 15. Adjust the CV joint-to-boot spacing to specification. 16. NOTE: The air should be released only after adjusting the CV joint to boot spacing. Insert a dulled screwdriver blade to relieve built up air pressure in the front wheel driveshaft joint boot. 17. Use the CV Boot Clamp Installer to install the two inboard boot clamps. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front > Page 6348 18. Position the clamp protectors over the inboard boot clamps. 19. Install the front wheel driveshaft and joint, please refer to Transmission and Drivetrain/Drive Axles, Bearings and Joints/Axle Shaft Assembly/ Axle Shaft/Service and Repair/ See: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front > Page 6349 Axle Shaft: Service and Repair Rear Rear 8.8 Inch Ring Gear Removal 1. Raise and support the vehicle, 2. Remove the wheel and tire assembly. 3. Remove the differential housing cover and drain the lubricant. 4. Remove the rear brake drums. 5. Remove the differential pinion shaft. 1 Remove and discard the differential pinion shaft lock bolt. 2 Remove the differential pinion shaft. 6. CAUTION: Do not damage the rubber O-rings in the axle shaft grooves. Remove the U-washers. 1 Push the axle shafts. 2 Remove the U-washers. 7. CAUTION: Do not damage the inner wheel bearing oil seal. Remove the two axle shafts. Installation 1. Lubricate the lip of the inner wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front > Page 6350 2. CAUTION: Do not damage the inner wheel bearing oil seal. Install the two axle shafts. 3. CAUTION: Do not damage the rubber O-rings in the U-washer grooves. Install the U-washers. 1 Position the two U-washers on the button end of the axle shafts. 2 Pull the axle shafts outward. 4. NOTE: If a new pinion shaft lock bolt is unavailable coat the threads with Thread lock and Sealer E0AZ-19554-AA or equivalent meeting Ford specifications WSK-M2G315-A5 and ESE-M4G204-A2 prior to installation. Install the differential pinion shaft. 1 Align the hole in the differential pinion shaft with the case lock bolt hole. 2 Install a new differential pinion shaft lock bolt. 5. Install the rear brake drums. 6. Install the differential housing cover and fill the rear axle housing with 2.37 liters (5 pints) of Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 7. WARNING: Always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub or brake drum that contacts the wheel. Installing wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the lug nut to loosen and the wheel to come off while the vehicle is in motion, causing loss of control. Clean the wheel hub and mounting surfaces. 8. Install the tire and wheel assembly. Rear 9.75 Inch Ring Gear Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front > Page 6351 Removal 1. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. Remove the differential housing cover. - Drain the lubricant. 4. Remove the rear brake system. 5. Remove the differential pinion shaft. 1 Remove the differential pinion shaft lock bolt. 2 Remove the differential pinion shaft. 6. CAUTION: Do not damage the rubber O-rings in the U-washer grooves. Remove the U-washers. 1 Push the axle shafts inboard. 2 Remove the U-washers. 7. CAUTION: Do not damage the inner wheel bearing oil seal. Remove the two axle shafts. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front > Page 6352 1. Lubricate the lip of the inner wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 2. CAUTION: Do not damage the inner wheel bearing oil seal. Install the two axle shafts. 3. CAUTION: Do not damage the rubber O-rings in the U-washer grooves. Install the U-washers. 1 Position the two U-washer on the button ends of the axle shafts. 2 Pull the axle shafts outward. 4. NOTE: If a new pinion shaft lock bolt is unavailable coat the threads with Thread lock and Sealer E0AZ-19554-AA or equivalent meeting Ford specifications WSK-M2G315-A5 and ESE-M4G204-A2 prior to installation. Install the differential pinion shaft. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Front > Page 6353 1 Align the hole in the differential pinion shaft with the case lock bolt hole. 2 Install a new lock bolt. 5. Install the rear brake drums. 6. Install the axle housing cover and fill the rear axle housing with 2.4 liters (5.5 pints) of Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 7. Install the tire and wheel assembly. 8. Lower the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Page 6354 Axle Shaft: Tools and Equipment Special Tool Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair Seals and Gaskets: Service and Repair Refer to Wheel Bearing for service procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6362 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6363 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6364 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6365 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6366 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6367 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6368 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6369 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6370 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6371 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6372 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6373 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6374 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6375 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6376 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6377 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6378 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6379 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6380 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6381 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6382 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6383 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6384 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6385 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6386 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6387 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6388 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6389 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6390 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6391 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6392 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6393 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6394 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6395 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6396 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6397 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6398 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6399 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6400 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6401 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6402 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6403 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6404 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6405 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6406 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6407 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6408 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6409 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6410 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6411 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6412 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6413 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6414 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6415 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6416 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6417 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6418 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6419 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6420 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6421 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6422 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6423 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6424 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6425 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6426 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6427 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6428 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6429 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6430 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6431 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6432 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6433 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6434 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6435 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6436 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6437 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6438 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6439 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6440 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6441 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6442 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6443 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6444 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6445 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6446 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6447 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6448 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6449 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6450 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6451 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6452 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6453 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6454 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6455 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6456 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Mechanical Specifications Wheel Bearing: Mechanical Specifications Maximum Axle Shaft End Play 0.762 mm Maximum Axle Shaft End Play 0.762 mm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Mechanical Specifications > Page 6459 Wheel Bearing: Fluid Type Specifications 8.8 Inch Ring Gear - Lubricate the new rear wheel bearing. Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. - Lubricate the lip of the new inner wheel bearing oil seal. Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 9.75 Inch Ring Gear - Lubricate the new rear wheel bearing. Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. - Lubricate the lip of the new inner wheel bearing oil seal. Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 6460 Wheel Bearing: Service Precautions CAUTION: Use only a grease that is recommended for wheel bearing applications. Use of the improper grease can cause bearing damage. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > 8.8-Inch Ring Gear Wheel Bearing: Service and Repair 8.8-Inch Ring Gear Special Tools Special Tools Removal 1. Remove the axle shaft. 2. NOTE: If the inner wheel bearing oil seal is leaking, the rear axle housing vent may be plugged. Using the special tools, remove the rear axle bearing and inner wheel bearing oil seal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > 8.8-Inch Ring Gear > Page 6463 Installation 1. Lubricate the new rear wheel bearing. - Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 2. Use the special tools to install the rear wheel bearing. 3. Lubricate the lip of the new inner wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tools, install the inner wheel bearing oil seal. 5. Install the axle shaft. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > 8.8-Inch Ring Gear > Page 6464 Wheel Bearing: Service and Repair 9.75-Inch Ring Gear Special Tools Special Tools Removal 1. Remove the axle shaft. 2. NOTE: If the inner wheel bearing oil seal is leaking, the rear axle housing vent may be plugged. Using the special tools, remove the rear wheel bearing and inner wheel bearing oil seal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > 8.8-Inch Ring Gear > Page 6465 Installation 1. Lubricate the new rear wheel bearing. - Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new inner wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tools, install the inner wheel bearing oil seal. 5. Install the axle shafts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Page 6466 Wheel Bearing: Tools and Equipment Special Tools Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications TORQUE SPECIFICATIONS Front Axle Hub Nut ........................................................................................................................................................... 255-345 Nm (188-254 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair Center Support: Service and Repair Special Tools Disassembly 1. Remove the driveshaft. 2. CAUTION: Do not clamp the driveshaft in the jaws of a vise or similar holding fixture. Remove the driveshaft slip-yoke boot. 1 With the front driveshaft on a bench, cut and discard the driveshaft slip-yoke boot clamps. 2 Separate the driveshaft slip-yoke from the splined stub shaft on the driveshaft. 3. Remove the driveshaft slip-yoke boot. - Inspect the driveshaft slip-yoke boot for damage and install new if required. 4. Inspect the lubricant for contamination. If contaminated, disassemble the driveshaft and inspect the stub shaft and driveshaft slip-yoke for wear. Install new components as needed. If necessary, separate the coupling shaft from the slip-yoke. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair > Page 6475 5. Remove the center bearing retainer, the bracket and the rubber insulator. 1 Remove the driveshaft center bearing retainer. 2 Remove the driveshaft center bearing bracket. 3 Remove the rubber insulator. 6. Using a suitable press, remove the center bearing and bearing retainer off the coupling shaft. 7. Press the dust slinger off the coupling shaft. Assembly Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair > Page 6476 1. Press the dust slinger on the coupling shaft. 2. NOTE: Press the bearing on the coupling shaft with the turned-in lip toward the dust slinger. NOTE: The driveshaft center bearing bracket must be installed with the deep flange rearward. Install the driveshaft center bearing support. 1 Install the rubber insulator in the driveshaft center bearing bracket. 2 Using a suitable press, install the driveshaft center bearing support assembly onto the coupling shaft. 3. Install the driveshaft center bearing retainer. 4. Slide the small opening end of the driveshaft slip-yoke boot on the splined stub shaft as far as it will travel. 5. Install the driveshaft slip-yoke boot clamp, and use Keystone Clamp Pliers to crimp the driveshaft slip-yoke boot clamp. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair > Page 6477 6. Install the driveshaft slip-yoke. 1 Lubricate the stub shaft splines, and pull the differential slip-yoke boot towards the driveshaft. Use Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B. 2 Fill the differential slip-yoke boot with approximately 10 grams of lubricant. Use Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B. 3 Position the driveshaft slip-yoke boot clamp. 4 Align the blind splines, and install the driveshaft slip-yoke. 7. Install the large driveshaft slip-yoke boot clamp. 1 Remove any excess grease from the driveshaft slip-yoke boot and driveshaft slip-yoke surfaces. 2 Position the differential slip-yoke boot over the driveshaft slip-yoke boot groove. 3 Position the driveshaft slip-yoke to specification from the driveshaft weld to the U-joint centerline. 4 Bleed air from the driveshaft slip-yoke boot. 5 Use Keystone Clamp Pliers to crimp the large driveshaft slip-yoke boot clamp. 8. Reassemble the coupling shaft. 9. Reinstall the driveshaft assembly in the vehicle. 10. NOTE: If a vibration exists, insert 1.59 mm (1/16 inch) shims between the driveshaft center bearing bracket and support plate (on the bolt ends of the driveshaft center bearing bracket) to reduce compression of the rubber insulator as required. Road test the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Center Support > Component Information > Service and Repair > Page 6478 Special Tool Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Customer Interest: > 04-1-6 > Jan > 04 > Driveline Clunking/Grunting Noise/Shudder Drive/Propeller Shaft: Customer Interest Driveline - Clunking/Grunting Noise/Shudder Article No. 04-1-6 01/26/04 ^ NOISE - DRIVELINE CLUNKING/GRUNTING NOISE OR SHUDDER SENSATION DURING LIGHT TO MODERATE ACCELERATION AND/OR BRAKING ^ TRANSMISSION - DRIVELINE CLUNKING/GRUNTING NOISE OR SHUDDER SENSATION DURING LIGHT TO MODERATE ACCELERATION AND/OR BRAKING FORD: 1998-2004 F-150 ISSUE Some 1998-2004 F-150 4X4 vehicles with a one piece drive shaft may exhibit a clunking or grunting noise and/or a shudder sensation from the driveline. The condition will typically occur during fight to moderate acceleration from a stop and/or braking. This may be caused by the slip yoke not sliding smoothly on the transfer case output shaft splines. ACTION To service, lubricate the slip yoke with Teflon Grease (D2AZ-19590-A). Refer to the following Service Procedure. SERVICE PROCEDURE 1. Road test the vehicle to verify the condition. 2. Remove the driveshaft per Section 205-01 of the Workshop Manual. NOTE INDEX (MARK) THE DRIVESHAFT YOKE TO AXLE FLANGE FOR REASSEMBLY. 3. Lubricate the slip yoke with 7-13 grams (0.25-0.46 oz.) of Teflon Grease (D2AZ-19590-A). 4. Re-index and reinstall the driveshaft per Workshop Manual. 5. Check the transfer case fluid level and add MERCON Automatic Transmission Fluid XT-2-QDX if necessary. 6. Road test to verify the condition is corrected. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 040106A Lubricate The Slip Yoke 1.0 Hr. With Teflon Grease Vehicles With One-Piece Driveshaft (Includes Time To Remove And Install Driveshaft) DEALER CODING CONDITION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Customer Interest: > 04-1-6 > Jan > 04 > Driveline Clunking/Grunting Noise/Shudder > Page 6487 BASIC PART NO. CODE 4602 42 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-1-6 > Jan > 04 > Driveline - Clunking/Grunting Noise/Shudder Drive/Propeller Shaft: All Technical Service Bulletins Driveline - Clunking/Grunting Noise/Shudder Article No. 04-1-6 01/26/04 ^ NOISE - DRIVELINE CLUNKING/GRUNTING NOISE OR SHUDDER SENSATION DURING LIGHT TO MODERATE ACCELERATION AND/OR BRAKING ^ TRANSMISSION - DRIVELINE CLUNKING/GRUNTING NOISE OR SHUDDER SENSATION DURING LIGHT TO MODERATE ACCELERATION AND/OR BRAKING FORD: 1998-2004 F-150 ISSUE Some 1998-2004 F-150 4X4 vehicles with a one piece drive shaft may exhibit a clunking or grunting noise and/or a shudder sensation from the driveline. The condition will typically occur during fight to moderate acceleration from a stop and/or braking. This may be caused by the slip yoke not sliding smoothly on the transfer case output shaft splines. ACTION To service, lubricate the slip yoke with Teflon Grease (D2AZ-19590-A). Refer to the following Service Procedure. SERVICE PROCEDURE 1. Road test the vehicle to verify the condition. 2. Remove the driveshaft per Section 205-01 of the Workshop Manual. NOTE INDEX (MARK) THE DRIVESHAFT YOKE TO AXLE FLANGE FOR REASSEMBLY. 3. Lubricate the slip yoke with 7-13 grams (0.25-0.46 oz.) of Teflon Grease (D2AZ-19590-A). 4. Re-index and reinstall the driveshaft per Workshop Manual. 5. Check the transfer case fluid level and add MERCON Automatic Transmission Fluid XT-2-QDX if necessary. 6. Road test to verify the condition is corrected. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 040106A Lubricate The Slip Yoke 1.0 Hr. With Teflon Grease Vehicles With One-Piece Driveshaft (Includes Time To Remove And Install Driveshaft) DEALER CODING CONDITION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-1-6 > Jan > 04 > Driveline - Clunking/Grunting Noise/Shudder > Page 6493 BASIC PART NO. CODE 4602 42 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive/Propeller Shaft: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference Oil Pressure Sender: All Technical Service Bulletins Oil Pressure Sending Unit - Drip Shield Interference Article No. 01-4-2 3/05/01 ENGINE - 5.4L - OIL SENDING UNIT INTERFERENCE FIT AT ENGINE OIL DRIP SHIELD - 4X4 VEHICLES EQUIPPED WITH 5.4L ENGINE ONLY FORD: 1998 F-250 LD 1998-2001 EXPEDITION, F-150 1999-2001 SUPER DUTY F SERIES LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit the engine oil sending unit contacting the oil drip shield attached to the front axle. This may be caused by tight tolerances between the engine oil sending unit and the engine oil drip shield. This may cause a malfunction of the engine oil sending unit. ACTION If the engine oil sending unit needs to be replaced due to contact with the drip shield, modify the engine oil drip shield as shown. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE IF THE ENGINE OIL SENDING UNIT NEEDS TO BE REPLACED IN SERVICE, MODIFY THE ENGINE OIL DRIP SHIELD BEFORE INSTALLING THE NEW ENGINE OIL SENDING UNIT. 1. Remove oil drip shield from front axle. This shield is attached to the front axle by three (3) bolts. 2. Modify shield as shown (Figure 1). Remove excess material from shield. Remove any sharp edges or burrs upon finishing cutting operation. 3. Reinstall engine oil drip shield. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive/Propeller Shaft: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference > Page 6499 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODE OASIS CODES: 401000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > All Other Service Bulletins for Drive/Propeller Shaft: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference > Page 6505 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODE OASIS CODES: 401000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Page 6506 Drive/Propeller Shaft: Specifications Driveshaft Bolts 112 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Page 6507 Drive/Propeller Shaft: Diagrams DRIVESHAFT - REAR, ONE-PIECE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Page 6508 DRIVESHAFT - REAR, TWO-PIECE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Page 6509 DRIVESHAFT - FRONT Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Page 6510 Drive/Propeller Shaft: Description and Operation DRIVESHAFT - REAR, ONE-PIECE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Page 6511 DRIVESHAFT - REAR, TWO-PIECE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Technical Service Bulletins > Page 6512 DRIVESHAFT - FRONT The driveshaft is a tubular shaft which transfers torque from the engine, through the transmission to the rear axle. Driveshafts; differ in length, diameter, and type of slip-yoke to accommodate various wheelbase and powertrain combinations. The two-piece driveshaft has a rear driveshaft and a front coupling shaft. The two-piece driveshaft incorporates three single cardan universal joints and is supported with a driveshaft center bearing support mounted to the frame. NOTE: Whenever the vehicle is raised on a hoist, inspect the universal joint slip yoke boot for rips or holes. Install new components if required. NOTE: All front driveshafts are balanced. If undercoating the vehicle, protect the driveshaft and universal joints to prevent overspray of any undercoating material. The front driveshaft is connected to the case and the front drive axle by driveshaft flange yokes. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > One-Piece Drive/Propeller Shaft: Service and Repair One-Piece Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. With the vehicle in neutral, raise and support the vehicle. 2. Index the driveshaft to driveshaft rear axle pinion flange. 3. Remove the driveshaft. 1 Remove the four driveshaft to driveshaft rear axle pinion flange bolts, and disconnect the driveshaft. Index-mark the driveshaft slip yoke to the transmission output shaft. 2 Lower the driveshaft, and slide the driveshaft rearward off the transmission output shaft. Plug the extension housing to prevent fluid loss. Installation 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > One-Piece > Page 6515 Drive/Propeller Shaft: Service and Repair Two-Piece Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. With the vehicle in neutral, raise and support the vehicle. 2. Index the driveshaft to driveshaft rear axle pinion flange. 3. Remove the four rear driveshaft bolts, and disconnect the rear driveshaft. 4. Remove the rear driveshaft. 1 Remove the two driveshaft center bearing support bolts. 2 Lower the rear driveshaft, and slide the driveshaft slip yoke rearward off the transmission output shaft and remove the rear driveshaft. Plug the extension housing to prevent fluid loss. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller Shaft > Component Information > Service and Repair > One-Piece > Page 6516 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > Customer Interest for Slip Yoke: > 04-26-6 > Dec > 04 > Driveline Clunk/Bump When Starting From A Stop Slip Yoke: Customer Interest Driveline - Clunk/Bump When Starting From A Stop TSB 04-26-6 12/31/04 CLUNK OR BUMP WHEN STARTING FROM A STOP FORD: 1997-2005 E-Series, F-150, F-Super Duty ISSUE Some 1997-2005 E-Series/F-150/F-Super Duty 4x2 vehicles may exhibit a driveline clunk or bump that occurs as the vehicle starts to move forward, following a stop. This condition may be caused by the slip yoke not sliding smoothly on the output shaft splines. ACTION Lubricate the slip yoke with Motorcraft PTFE Lubricant. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Verify the condition. 2. Remove the driveshaft per Workshop Manual Section 205-01. Be sure to index-mark the driveshaft during removal to maintain alignment during reinstallation. 3. Lubricate the slip yoke with 7-13 grams (0.25-0.46 oz.) of Motorcraft PTFE Lubricant. 4. Re-index and reinstall the driveshaft per Workshop Manual. 5. Verify the repair. Parts Block OTHER APPLICABLE ARTICLES: 04-1-6 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042606A F-iSO: Lubricate Driveshaft 1.0 Hrs. Slip-Yoke (Includes Time For Road Test To Verify Concern, Driveshaft R and I, And Road Test To Verify Repair) 042606A E-Series and F-Super 1.2 Hrs. Duty: Lubricate Driveshaft Slip-Yoke (Includes Time For Road Test To Verify Concern, Driveshaft R and I, And Road Test To Verify Repair) DEALER CODING CONDITION BASIC PART NO. CODE 4602 42 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > Customer Interest for Slip Yoke: > 04-26-6 > Dec > 04 > Driveline Clunk/Bump When Starting From A Stop > Page 6525 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > Customer Interest for Slip Yoke: > 04-1-6 > Jan > 04 > Driveline Clunking/Grunting Noise/Shudder Slip Yoke: Customer Interest Driveline - Clunking/Grunting Noise/Shudder Article No. 04-1-6 01/26/04 ^ NOISE - DRIVELINE CLUNKING/GRUNTING NOISE OR SHUDDER SENSATION DURING LIGHT TO MODERATE ACCELERATION AND/OR BRAKING ^ TRANSMISSION - DRIVELINE CLUNKING/GRUNTING NOISE OR SHUDDER SENSATION DURING LIGHT TO MODERATE ACCELERATION AND/OR BRAKING FORD: 1998-2004 F-150 ISSUE Some 1998-2004 F-150 4X4 vehicles with a one piece drive shaft may exhibit a clunking or grunting noise and/or a shudder sensation from the driveline. The condition will typically occur during fight to moderate acceleration from a stop and/or braking. This may be caused by the slip yoke not sliding smoothly on the transfer case output shaft splines. ACTION To service, lubricate the slip yoke with Teflon Grease (D2AZ-19590-A). Refer to the following Service Procedure. SERVICE PROCEDURE 1. Road test the vehicle to verify the condition. 2. Remove the driveshaft per Section 205-01 of the Workshop Manual. NOTE INDEX (MARK) THE DRIVESHAFT YOKE TO AXLE FLANGE FOR REASSEMBLY. 3. Lubricate the slip yoke with 7-13 grams (0.25-0.46 oz.) of Teflon Grease (D2AZ-19590-A). 4. Re-index and reinstall the driveshaft per Workshop Manual. 5. Check the transfer case fluid level and add MERCON Automatic Transmission Fluid XT-2-QDX if necessary. 6. Road test to verify the condition is corrected. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 040106A Lubricate The Slip Yoke 1.0 Hr. With Teflon Grease Vehicles With One-Piece Driveshaft (Includes Time To Remove And Install Driveshaft) DEALER CODING CONDITION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > Customer Interest for Slip Yoke: > 04-1-6 > Jan > 04 > Driveline Clunking/Grunting Noise/Shudder > Page 6530 BASIC PART NO. CODE 4602 42 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Slip Yoke: > 04-26-6 > Dec > 04 > Driveline - Clunk/Bump When Starting From A Stop Slip Yoke: All Technical Service Bulletins Driveline - Clunk/Bump When Starting From A Stop TSB 04-26-6 12/31/04 CLUNK OR BUMP WHEN STARTING FROM A STOP FORD: 1997-2005 E-Series, F-150, F-Super Duty ISSUE Some 1997-2005 E-Series/F-150/F-Super Duty 4x2 vehicles may exhibit a driveline clunk or bump that occurs as the vehicle starts to move forward, following a stop. This condition may be caused by the slip yoke not sliding smoothly on the output shaft splines. ACTION Lubricate the slip yoke with Motorcraft PTFE Lubricant. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Verify the condition. 2. Remove the driveshaft per Workshop Manual Section 205-01. Be sure to index-mark the driveshaft during removal to maintain alignment during reinstallation. 3. Lubricate the slip yoke with 7-13 grams (0.25-0.46 oz.) of Motorcraft PTFE Lubricant. 4. Re-index and reinstall the driveshaft per Workshop Manual. 5. Verify the repair. Parts Block OTHER APPLICABLE ARTICLES: 04-1-6 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 042606A F-iSO: Lubricate Driveshaft 1.0 Hrs. Slip-Yoke (Includes Time For Road Test To Verify Concern, Driveshaft R and I, And Road Test To Verify Repair) 042606A E-Series and F-Super 1.2 Hrs. Duty: Lubricate Driveshaft Slip-Yoke (Includes Time For Road Test To Verify Concern, Driveshaft R and I, And Road Test To Verify Repair) DEALER CODING CONDITION BASIC PART NO. CODE 4602 42 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Slip Yoke: > 04-26-6 > Dec > 04 > Driveline - Clunk/Bump When Starting From A Stop > Page 6536 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Slip Yoke: > 04-1-6 > Jan > 04 > Driveline - Clunking/Grunting Noise/Shudder Slip Yoke: All Technical Service Bulletins Driveline - Clunking/Grunting Noise/Shudder Article No. 04-1-6 01/26/04 ^ NOISE - DRIVELINE CLUNKING/GRUNTING NOISE OR SHUDDER SENSATION DURING LIGHT TO MODERATE ACCELERATION AND/OR BRAKING ^ TRANSMISSION - DRIVELINE CLUNKING/GRUNTING NOISE OR SHUDDER SENSATION DURING LIGHT TO MODERATE ACCELERATION AND/OR BRAKING FORD: 1998-2004 F-150 ISSUE Some 1998-2004 F-150 4X4 vehicles with a one piece drive shaft may exhibit a clunking or grunting noise and/or a shudder sensation from the driveline. The condition will typically occur during fight to moderate acceleration from a stop and/or braking. This may be caused by the slip yoke not sliding smoothly on the transfer case output shaft splines. ACTION To service, lubricate the slip yoke with Teflon Grease (D2AZ-19590-A). Refer to the following Service Procedure. SERVICE PROCEDURE 1. Road test the vehicle to verify the condition. 2. Remove the driveshaft per Section 205-01 of the Workshop Manual. NOTE INDEX (MARK) THE DRIVESHAFT YOKE TO AXLE FLANGE FOR REASSEMBLY. 3. Lubricate the slip yoke with 7-13 grams (0.25-0.46 oz.) of Teflon Grease (D2AZ-19590-A). 4. Re-index and reinstall the driveshaft per Workshop Manual. 5. Check the transfer case fluid level and add MERCON Automatic Transmission Fluid XT-2-QDX if necessary. 6. Road test to verify the condition is corrected. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 040106A Lubricate The Slip Yoke 1.0 Hr. With Teflon Grease Vehicles With One-Piece Driveshaft (Includes Time To Remove And Install Driveshaft) DEALER CODING CONDITION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Slip Yoke: > 04-1-6 > Jan > 04 > Driveline - Clunking/Grunting Noise/Shudder > Page 6541 BASIC PART NO. CODE 4602 42 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > Page 6542 Slip Yoke: Service and Repair Special Tools Disassembly 1. CAUTION: Do not clamp the driveshaft in the jaws of a vise or similar holding fixture. Remove the driveshaft slip yoke boot. 1 With the front driveshaft on a bench, cut and discard the driveshaft slip yoke boot clamps. 2 Separate the driveshaft slip yoke from the splined stub shaft on the driveshaft. 2. Remove the driveshaft slip yoke boot. - Inspect the driveshaft slip yoke boot for damage and install a new boot, if necessary. 3. Inspect the lubricant for contamination. If contaminated, disassemble the driveshaft and inspect the stub shaft and driveshaft slip yoke for wear. Install new components as needed. Assembly Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > Page 6543 1. Slide the small opening end of the driveshaft slip yoke boot on the splined stub shaft as far as it will travel. 2. Install the driveshaft slip yoke boot clamp and use Keystone Clamp Pliers to crimp the driveshaft slip yoke boot clamp. 3. Install the driveshaft slip yoke. 1 Lubricate the stub shaft splines, and pull the driveshaft slip yoke boot towards the driveshaft. Use Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B. 2 Fill the driveshaft slip yoke boot with approximately 10 grams of lubricant. Use Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B. 3 Position the large driveshaft slip yoke boot clamp. 4 Align the blind splines, and install the driveshaft slip yoke. 4. Install the large driveshaft slip yoke boot clamp. 1 Remove any excess grease from the driveshaft slip yoke boot and driveshaft slip yoke surfaces. 2 Position the driveshaft slip yoke boot over the driveshaft slip yoke boot groove. 3 Position the driveshaft slip yoke to specification from the driveshaft weld to the U-joint centerline. 4 Bleed air from the driveshaft slip yoke boot. 5 Use Keystone Clamp Pliers to crimp the large driveshaft slip yoke boot clamp. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Description and Operation Universal Joint: Description and Operation The universal joints are: lubed-for-life design and require no lubrication. - equipped with nylon thrust washers, located at each base of the bearing cup, which control end play, position the needle bearing and improve grease movement. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Disassembly and Assembly Universal Joint: Service and Repair Disassembly and Assembly Disassembly 1. CAUTION: Do not clamp the driveshaft in a vise or similar holding fixture. Place the driveshaft on a suitable workbench. 2. NOTE: If components are not marked and installed correctly, driveline imbalance can occur. Index the driveshaft components. 3. Clamp the U-joint Tool in a vise. 4. Remove the four driveshaft centering socket yoke universal joint snap rings. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Disassembly and Assembly > Page 6549 5. Remove the driveshaft centering socket yoke. 1 Position the driveshaft centering socket yoke in the U-joint Tool. 2 Press out a bearing cup. 3 Remove the driveshaft centering socket yoke. 6. Press out the driveshaft centering socket yoke universal joint bearing cups. 1 Position the yoke in the U-joint Tool. 2 Press out the bearing cup. 3 Rotate the yoke. 4 Press out the remaining bearing cup. 7. Remove the four remaining snap rings. 8. Remove the centering cup spring. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Disassembly and Assembly > Page 6550 9. Press out the driveshaft yoke bearing cups. 1 Position the yoke in the U-joint Tool. 2 Press out the bearing cup. 3 Rotate the yoke. 4 Press out the remaining bearing cup. 10. Press out the driveshaft yoke bearing cups. 1 Position the yoke in the U-joint Tool. 2 Press out the bearing cup. 3 Rotate the yoke. 4 Press out the remaining bearing cup. Assembly 1. Install a new bearing cup into the driveshaft yoke. 1 Start a new bearing cup into the driveshaft yoke. 2 Position the new spider in the driveshaft yoke. 3 Position the driveshaft in the U-joint Tool. 4 Press the bearing cup below the yoke surface. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Disassembly and Assembly > Page 6551 2. Install a new bearing cup into the driveshaft center yoke. 1 Start a new bearing cup into the driveshaft center yoke. 2 Position the driveshaft center yoke in the U-joint Tool. 3 Press the bearing cup below the driveshaft center yoke surface. Rotate the driveshaft 180° and repeat for the other bearing cup. 3. Install a new centering cup spring. 4. Install four new snap rings. 5. Install a new bearing cup into the driveshaft centering socket yoke. 1 Start a new bearing cup into the driveshaft centering socket yoke. 2 Position the new spider in the driveshaft centering socket yoke. 3 Position the driveshaft centering socket yoke in the U-joint Tool. 4 Press the bearing cup below the driveshaft centering socket yoke surface. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Disassembly and Assembly > Page 6552 6. Install a new bearing cup into the driveshaft yoke. 1 Start a new bearing cup into the driveshaft yoke. 2 Position the new spider in the driveshaft yoke. 3 Position the driveshaft in the U-joint Tool. 4 Press the bearing cup below the yoke surface. 7. Install new snap rings. 8. NOTE: Do not strike the bearings. Check the U-joints for freedom of movement. If bearings are binding, strike the yoke with a plastic hammer. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Disassembly and Assembly > Page 6553 Universal Joint: Service and Repair Single Cardan, Flange Yoke - Disassembly and Assembly Disassembly 1. Remove the driveshaft. 2. CAUTION: Do not clamp the driveshaft in a vise or similar holding fixture. Place the driveshaft on a suitable workbench, being careful not to damage the tube. 3. NOTE: If components are not marked and installed correctly, driveline imbalance can occur. Index-mark the positions of the driveshaft components. 4. Clamp the U-joint Tool in a vise. 5. Remove all four of the snap rings. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Disassembly and Assembly > Page 6554 6. Remove the driveshaft flange yoke. 1 Position the driveshaft flange yoke in the U-joint Tool. 2 Press out a bearing cup. 3 Remove the driveshaft flange yoke. 4 Press on the spider to remove the remaining bearing cup. 5 Remove the driveshaft flange yoke. 7. Remove the spider. 1 Reposition the driveshaft in the U-joint Tool. 2 Press out the bearing cup. 3 Rotate the driveshaft. 4 Press on the spider to remove the remaining bearing cup. 5 Remove the spider. 8. Clean the yoke area at the end of the driveshaft. Assembly 1. NOTE: Universal joint kits are to be installed as complete assemblies only. Do not mix components from other U-joint kits. Install the spider. 1 Start a new bearing cup into the driveshaft yoke. Check the needle bearings for correct positioning. 2 Position the new spider in the driveshaft yoke. 3 Position the driveshaft in the U-joint Tool. 4 Press the bearing cup to just below the snap ring groove. Repeat for the other bearing cup. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Disassembly and Assembly > Page 6555 2. Inspect the driveshaft flange yoke. Install new if necessary. 3. Install the driveshaft flange yoke. 1 Start a new bearing cup into the driveshaft flange yoke. Check the needle bearings for correct positioning. 2 Position the driveshaft flange yoke. 3 Position the driveshaft in the U-joint Tool. 4 Press the bearing cup to just below the snap ring groove. Repeat for the other bearing cup. 4. NOTE: Use the yellow snap rings supplied in the kit to assemble the universal joint (U-joint). If difficulty is encountered with the yellow snap rings, install the black snap rings. Remove the driveshaft from the U-joint Tool, and install the four snap rings. 5. NOTE: Do not strike the bearings. Check the U-joints for freedom of movement. If binding, strike the yoke with a brass or plastic hammer. 6. Install the driveshaft. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Disassembly and Assembly > Page 6556 Universal Joint: Service and Repair Single Cardan, Slip Yoke - Disassembly and Assembly Disassembly 1. CAUTION: Under no circumstances is the driveshaft assembly to be clamped in the jaws of a vise or similar holding fixture. Denting or localizing fracture can result, causing driveshaft failure during vehicle operation. Place the driveshaft on a suitable workbench. Be careful not to damage the tube. 2. NOTE: If components are not marked and therefore installed incorrectly, driveline imbalance can occur. Index-mark the driveshaft components. 3. Clamp U-joint Tool in a vise. 4. Remove all four of the snap rings. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Disassembly and Assembly > Page 6557 5. NOTE: If necessary, use a pair of pliers to remove a bearing cup if it cannot be pressed out all the way. Remove the driveshaft slip-yoke. 1 Position the driveshaft slip-yoke in the U-joint Tool. 2 Press out a bearing cup. 3 Rotate the driveshaft slip-yoke. 4 Press on the spider to remove the remaining bearing cup. 5 Remove the driveshaft slip-yoke. 6. Repeat Step 5 to remove the remaining bearing cups and spider from the driveshaft. 7. Clean the yoke area at each end of the driveshaft. Assembly 1. NOTE: Universal Joint Service Kits are to be installed as complete assemblies only. Do not mix components from other U-joint Kits. Install the bearing cup. 1 Start a new bearing cup into the driveshaft yoke. Check the needle bearings for correct positioning. 2 Position the new spider in the driveshaft yoke. 3 Using the U-joint Tool, press the bearing cup to just below the snap ring groove. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Disassembly and Assembly > Page 6558 2. NOTE: Use the yellow snap rings supplied in the kit to assemble the universal joint (U-joint). If difficulty is encountered with the yellow snap rings, install the black snap rings. Remove the driveshaft from the U-joint Tool, and install the snap ring. 3. Repeat Steps 1 and 2 to install the opposite side of the driveshaft yoke. 4. Inspect the driveshaft slip-yoke. Install a new yoke, if necessary. 5. Repeat Steps 1 and 2 to install the remaining new bearing cups, spider, driveshaft slip-yoke, and the snap rings. 6. NOTE: Do not strike the bearings. Check the U-joints for freedom of movement. If binding, strike the yoke with a brass or plastic hammer. 7. Install the driveshaft. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Page 6559 Special Tool Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications Flexplate to Crankshaft 73-87 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 6563 Flex Plate: Service and Repair Removal All Vehicles 1. Remove the transmission. 2. Remove the bolts. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 6564 1. Position the flywheel and install the bolts tighten the bolts in two stages. ^ Stage 1: Loosely install the bolts ^ Stage 2: Tighten the bolts in sequence shown. All Vehicles 2. Install the transmission. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications Flywheel: Specifications Flywheel Runout 0.2 mm Flywheel Bolts 73-87 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Testing and Inspection > Flywheel Check Flywheel: Testing and Inspection Flywheel Check 1. Inspect flywheel for: - Cracks. - Heat checks or other damage. - Machine friction surface of if scored or worn. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Testing and Inspection > Flywheel Check > Page 6570 Flywheel: Testing and Inspection Flywheel Runout Check Special Tools 1. Use Dial Indicator/Magnetic Base to inspect flywheel runout. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Service and Repair > Removal and Installation Flywheel: Service and Repair Removal and Installation Removal All Vehicles 1. Remove the clutch components. 2. Remove the bolts. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Service and Repair > Removal and Installation > Page 6573 1. Position the flywheel and install the bolts tighten the bolts in two stages. ^ Stage 1: Loosely install the bolts ^ Stage 2: Tighten the bolts in sequence shown. All Vehicles 2. Install the transmission clutch components. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Service and Repair > Removal and Installation > Page 6574 Flywheel: Service and Repair Flywheel Dowels Removal 1. NOTE: Take care not to damage the flywheel dowel holes or surface areas around the flywheel dowel during removal. Remove the flywheel dowels by using a drift pin where the flywheel dowel is installed in an open hole and locking pliers where the flywheel dowel is installed in a blind hole. Installation 1. NOTE: Care should be taken to drive the flywheel dowel squarely into place until fully seated and to not damage surrounding surface areas. Install all flywheel dowels by driving them into place using a brass or plastic mallet. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Service and Repair > Removal and Installation > Page 6575 Flywheel: Service and Repair Flywheel Housing to Block Dowels Removal 1. NOTE: Take care not to damage the flywheel housing to block dowel holes or surface areas around the flywheel housing to block dowel hole during removal. Remove the flywheel housing to block dowel using a drift pin where the flywheel housing to block dowel is installed in an open hole and locking pliers where the flywheel housing to block dowel is installed in a blind hole. Installation 1. NOTE: Care should be taken to drive the flywheel housing to block dowel squarely into place until fully seated without damaging the surrounding surface areas. Install all flywheel housing to block dowels by driving them into place using a brass or plastic mallet. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Service and Repair > Page 6576 Special Tool Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Adjustments Shift Indicator: Adjustments 1. Remove the upper instrument panel steering column cover. 2. Place the gearshift lever in the (D) position. - Rotate the gearshift lever clockwise until it bottoms out (first gear), then rotate two detents counterclockwise (D) position). 3. Hang an eight pound weight on the gearshift lever. 4. Center the pointer in the middle of the (D) position. - Rotate the thumb wheel located on the bottom of the steering column to adjust the pointer. 5. Remove the eight pound weight. 6. Carefully move the gearshift lever from detent to detent and compare with transmission settings. Readjust if necessary. 7. Install the upper instrument panel steering column cover. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Four Wheel Drive Indicator Lamp: Customer Interest Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 6591 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Four Wheel Drive Indicator Lamp: All Technical Service Bulletins Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 6597 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > 4X4 High Indicator Four Wheel Drive Indicator Lamp: Description and Operation 4X4 High Indicator The 4X4 high indicator will be illuminated when the vehicle is in 4X4 high mode and the GEM sends a ground signal to the instrument cluster. The 4X4 high indicator will prove out when the ignition switch is placed in the START position and then in the RUN position. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > 4X4 High Indicator > Page 6600 Four Wheel Drive Indicator Lamp: Description and Operation Low Range Indicator The LOW RANGE indicator Will be illuminated when the vehicle is in 4X4 low and the Powertrain Control Module (PCM) sends a message to the instrument cluster via the SCP network. The low range indicator will prove out when the ignition switch is placed in the START position and then in the RUN position. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Page 6601 Four Wheel Drive Indicator Lamp: Testing and Inspection Refer to Instrument Panel/Testing and Inspection/Procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component Information > Specifications Case: Specifications Case Cover Bolts 16-22 Nm Case Plug 40-58 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Countershaft, M/T > Component Information > Specifications Countershaft: Specifications Countershaft Locknut 128-196 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Drain Plug, M/T > Component Information > Specifications Drain Plug: Specifications Drain Plug 40-58 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Extension Housing, M/T > Component Information > Specifications Extension Housing: Specifications Extension Housing Bolts ............................................................................................................................................................ 32-46 Nm (24-33 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Extension Housing, M/T > Component Information > Specifications > Page 6615 Extension Housing: Service and Repair Special Tools Removal 1. Disconnect the battery ground cable. 2. If equipped, turn the air suspension switch off. 3. Raise and support the vehicle. 4. Drain the transmission fluid. 5. Remove and support the rear driveshaft. 1 Remove the bolts. 2 Remove the rear driveshaft. 6. Remove the. 1 Disconnect the electrical connector. 2 Remove the bolt. 3 Remove the VSS. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Extension Housing, M/T > Component Information > Specifications > Page 6616 7. Use (A) the High-Lift Jack to support the (B) transmission. - Secure the transmission with the (C) strap. 8. Remove the transmission mount nuts. 9. Remove the heat shield bolts (one each side). 10. Remove the crossmember. 1 Remove the bolts (three each side). 2 Remove the crossmember. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Extension Housing, M/T > Component Information > Specifications > Page 6617 11. Remove the transmission mount. 1 Remove the bolts. 2 Remove the transmission mount. 12. Remove the exhaust pipe bracket. 1 Remove the nuts. 2 Remove the exhaust pipe bracket. 13. Lower the transmission to access extension housing bolts. 14. Use (A) Seal Remover to remove the (B) extension housing seal. 15. Remove the extension housing. 1 Remove the bolts. 2 Remove the extension housing. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Extension Housing, M/T > Component Information > Specifications > Page 6618 16. Remove the speedometer drive gear. 1 Remove the speedometer gear retaining ring. 2 Remove the speedometer drive gear. Installation 1. Install the speedometer drive gear. 1 Install the speedometer drive gear. 2 Install the speedometer gear retaining ring. 2. NOTE: Extension housing must be installed within four minutes after applying silicone. Apply a small bead of silicone rubber to the surface of the extension housing. Use Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specification ESB-M4G92-A. 3. Install the extension housing. 1 Position the extension housing. 2 Install the bolts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Extension Housing, M/T > Component Information > Specifications > Page 6619 4. Use (A) Extension Housing Seal Replacer to install a new (B) extension housing seal. 5. Raise and position the transmission. 6. Install the exhaust pipe bracket. 1 Position the exhaust pipe bracket. 2 Install the nuts. 7. Install the transmission mount. 1 Position the transmission mount. 2 Install the bolts. 8. Install the crossmember. 1 Position the crossmember. 2 Install the bolts and nuts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Extension Housing, M/T > Component Information > Specifications > Page 6620 9. Install the heat shield bolts (one each side). 10. Remove the High-Lift Jack. 11. Install the transmission mount nuts. 12. Install the VSS. 1 Install the VSS. 2 Install the bolt. 3 Connect the electrical connector. 13. Install the rear driveshaft. 1 Position the rear driveshaft. 2 Install the bolts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Extension Housing, M/T > Component Information > Specifications > Page 6621 14. Fill (A) transmission with fluid until it reaches the bottom of the (B) fill port and install the (C). - Use Motorcraft MERCON Multi-Purpose Automatic Transmission Fluid XT-2-QDX or DDX or equivalent Mercon Automatic Transmission Fluid. MERCON(R) automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4. 15. Lower the vehicle. 16. Connect the the battery ground cable. 17. If equipped with air suspension, reactivate the system by turning on the air suspension switch. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Extension Housing, M/T > Component Information > Specifications > Page 6622 Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fill Plug, M/T > Component Information > Specifications Fill Plug: Specifications Fill Plug 40-58 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > M/T - Mercon(R) V ATF Usage Information Fluid - M/T: Technical Service Bulletins M/T - Mercon(R) V ATF Usage Information TSB 06-26-1 01/08/07 MERCON ATF IS BEING REPLACED BY MERCON V AS A SERVICE FLUID FOR SOME MANUAL TRANSMISSIONS FORD: 1981-2003 Escort 1984-1995 Thunderbird 1985-2007 Mustang 1985-1996 Bronco 1985-2007 Ranger 1986-1997 Aerostar 1991-2004 Explorer 1995-2007 F-150 1996-2007 F-Super Duty 2001-2003 Explorer Sport Trac, Explorer Sport LINCOLN: 2001-2002 Lincoln LS MERCURY: 1984-1995 Cougar 1987-1999 Tracer ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as the service fluid for manual transmissions originally requiring MERCON(R). ACTION Beginning immediately all manual transmission applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will continue until remaining inventory has been depleted. SERVICE PROCEDURE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > M/T - Mercon(R) V ATF Usage Information > Page 6630 Service manual transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON/MERCON(R) V. For proper fluid application on current and past model manual transmissions refer to the fluid usage chart. (Figure 1) WARNING FULL SYNTHETIC MANUAL TRANSMISSION FLUID (XT-M5-QS), SAE 75W-90 API GL-4 GEAR OIL (XY-75W90-QGL) AND SAE 75W-90 PREMIUM SYNTHETIC TRANSAXLE LUBRICANT (XT-75W90-QGT) ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS RECOMMENDING THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > M/T - Mercon(R) V ATF Usage Information > Page 6631 Parts Block WARRANTY STATUS: Information Only Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications Fluid - M/T: Capacity Specifications Capacity ............................................................................................................................................... .......................................................................... 1.9L Note; Fill to 1/4 to 9/16 inches below bottom of filler hole. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Capacity Specifications > Page 6634 Fluid - M/T: Fluid Type Specifications MERCON (r) ATF ................................................................................................................................ ............................................................... XT-2-QDX MERCON(R) automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Specifications > Page 6635 Fluid - M/T: Service Precautions DO NOT over fill transmission beyond normal capacity. This may cause fluid foaming and transmission damage. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Flywheel Gear, M/T > Component Information > Service and Repair Flywheel Gear: Service and Repair Removal WARNING: This procedure should be carried out only by a properly equipped and experienced acetylene torch operator. To avoid personal injury, tongs must be used or asbestos gloves worn when handling the heated flywheel ring gear. 1. Remove the flywheel. 2. CAUTION: Tap the flywheel ring gear evenly to prevent binding. Remove the flywheel ring gear from the flywheel. Evenly heat the flywheel ring gear and use a brass drift to drive the flywheel ring gear from the flywheel. Installation WARNING: This procedure should be carried out only by a properly equipped and experienced acetylene torch operator. To avoid personal injury, tongs must be used or asbestos gloves worn when handling the heated flywheel ring gear. 1. CAUTION: Do not heat the flywheel ring gear beyond 278°C (500°F). Use heat indicating crayons to prevent over-heating. CAUTION: Keep the torch moving to prevent hot spots. Evenly heat the flywheel ring gear. 2. Install the flywheel ring gear. - The bevel on the flywheel ring gear must face the rear of the flywheel. - Using a brass drift, install the flywheel ring gear onto the flywheel. 3. Install the flywheel. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Gear, M/T > Synchronizer Ring, M/T > Component Information > Specifications Synchronizer Ring: Specifications Synchronizer Blocking Ring to Gear ................................................................................................................................................. 1.5 mm (0.059 inch) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Output Shaft, M/T > Component Information > Specifications Output Shaft: Specifications Output Shaft Maximum Runout ..................................................................................................................................................... 0.05 mm (0.0019 inch) Output Shaft Locknut ......................................................................................................................................................... 216-274 Nm (160-202 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Reverse Gear Shaft > Component Information > Specifications Reverse Gear Shaft: Specifications Fifth/Reverse Lock Plate Bolt ......................................................................................................................................................... 8-10 Nm (6-8 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Reverse Idler Gear > Component Information > Technical Service Bulletins > Customer Interest for Reverse Idler Gear: > 99-3-2 > Feb > 99 > M/T - M5OD Vehicle Will Not Go Into Reverse Reverse Idler Gear: Customer Interest M/T - M5OD Vehicle Will Not Go Into Reverse Article No. 99-3-2 02/22/99 TRANSMISSION - M5OD - VEHICLE WILL NOT GO INTO REVERSE - VEHICLES BUILT THROUGH 11/1/1998 LIGHT TRUCK: 1997-99 F-150, F-250 LD ISSUE Some vehicles may experience a no reverse gear condition. This may be due to breakage of the reverse gear. ACTION Install a revised countershaft reverse gear and revised reverse idler gear. The new gears are more robust and should reduce the possibility of breakage of the reverse gear. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the transmission from the vehicle. Refer to Section 308-03 of the appropriate model year Workshop Manual for the detailed removal procedure. 2. Remove the reverse idler gear (-7141-) and countershaft reverse gear (-7N040-). Refer to Steps 1 through 14 of the Disassembly Procedure in Section 308-03 of the Workshop Manual for the detailed service procedure. 3. Install new Countershaft Reverse Gear (-7N040-) and new Reverse Idler Gear (-7141-). Refer to Steps 30 through 49 of the Assembly Procedure in Section 308-03 of the Workshop Manual for the detailed service procedure. 4. Install the transmission into the vehicle. Refer to Section 308-03 of the Workshop Manual for the detailed installation procedure. PART NUMBER PART NAME XL3Z-7N040-AA Countershaft Reverse Gear XL3Z-7141-AA Reverse Idler Gear OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 990302A Install New Transmission 3.6 Hrs. Gears DEALER CODING CONDITION BASIC PART NO. CODE 7141 01 OASIS CODES: 505000, 505200, 506000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Reverse Idler Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Reverse Idler Gear: > 99-3-2 > Feb > 99 > M/T - M5OD Vehicle Will Not Go Into Reverse Reverse Idler Gear: All Technical Service Bulletins M/T - M5OD Vehicle Will Not Go Into Reverse Article No. 99-3-2 02/22/99 TRANSMISSION - M5OD - VEHICLE WILL NOT GO INTO REVERSE - VEHICLES BUILT THROUGH 11/1/1998 LIGHT TRUCK: 1997-99 F-150, F-250 LD ISSUE Some vehicles may experience a no reverse gear condition. This may be due to breakage of the reverse gear. ACTION Install a revised countershaft reverse gear and revised reverse idler gear. The new gears are more robust and should reduce the possibility of breakage of the reverse gear. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the transmission from the vehicle. Refer to Section 308-03 of the appropriate model year Workshop Manual for the detailed removal procedure. 2. Remove the reverse idler gear (-7141-) and countershaft reverse gear (-7N040-). Refer to Steps 1 through 14 of the Disassembly Procedure in Section 308-03 of the Workshop Manual for the detailed service procedure. 3. Install new Countershaft Reverse Gear (-7N040-) and new Reverse Idler Gear (-7141-). Refer to Steps 30 through 49 of the Assembly Procedure in Section 308-03 of the Workshop Manual for the detailed service procedure. 4. Install the transmission into the vehicle. Refer to Section 308-03 of the Workshop Manual for the detailed installation procedure. PART NUMBER PART NAME XL3Z-7N040-AA Countershaft Reverse Gear XL3Z-7141-AA Reverse Idler Gear OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 990302A Install New Transmission 3.6 Hrs. Gears DEALER CODING CONDITION BASIC PART NO. CODE 7141 01 OASIS CODES: 505000, 505200, 506000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Reverse Idler Gear > Component Information > Technical Service Bulletins > Page 6662 Reverse Idler Gear: Specifications Reverse Idler Gear End Play ......................................................................................................................................... 0.1-0.2 mm (0.0039-0.0078 inch) Fifth/Reverse Hub End Play .......................................................................................................................................... 0.00-0.05 mm (0.00-0.0019 inch) Countershaft Reverse Gear ........................................................................................................................ End Play 0.25-0.35 mm (0.0098-0.0138 inch) Reverse Idler Shaft Bolt ........................................................................................................................................................... 79-117 Nm (58-86 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Output Shaft Speed Sensor Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Output Shaft Speed Sensor > Page 6668 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 6669 Transmission Speed Sensor: Service and Repair Removal 1. Remove the drive shaft. 2. Remove the rear transmission mount nuts. 3. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the TSS and OSS sensors will occur. Remove the rear transmission mount. 1 Raise the transmission up off the rear crossmember support. 2 Remove the bolts. 3 Remove the rear transmission mount. 4. Lower the transmission to gain access to the Turbine Shaft Speed (TSS) sensor, and the Output Shaft Speed (OSS) sensor. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 6670 5. Remove the Turbine Shaft Sensor (TSS). 1 Remove the bolt. 2 Remove the Turbine Shaft Sensor (TSS). 6. Remove the Output Shaft Speed (OSS) sensor. 1 Remove the bolt. 2 Remove the Output Shaft Speed (OSS) sensor. Installation 1. Install the Output Shaft Speed (OSS) sensor. 1 Lubricate the O-ring and install the Output Shaft Speed (OSS) sensor. 2 Install the bolt. 2. Install the Turbine Shaft Sensor (TSS). 1 Lubricate the O-ring and install the Turbine Shaft Sensor (TSS). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 6671 2 Install the bolt. 3. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the sensors will occur. Install the rear transmission mount. 1 Raise the transmission up. 2 Install the rear transmission mount. 3 Install the bolts. 4. Lower the transmission on to the rear crossmember support. 5. Install the rear transmission mount nuts. 6. Install the drive shaft. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Fork, M/T > Component Information > Specifications Shift Fork: Specifications Shift Fork to Synchronizer Sleeve 0.8 mm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Specifications Shifter M/T: Specifications Gearshift Lever Bolt 27-40 Nm Gear Selector Interlock Bolts 8-10 Nm Inner Gearshift Lever Boot Bolts 10-14 Nm Outer Gearshift Lever Boot Screws 5-9 Nm Shift Plate Bolts 8-10 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Specifications > Page 6678 Shifter M/T: Service and Repair Removal 1. Remove the screws. 2. Remove the gearshift lever. 1 Lift the outer gearshift boot. 2 Remove the bolt. 3 Remove the gearshift lever. 3. Remove the inner gearshift lever boot. 1 Remove the bolts. 2 Remove the inner gearshift lever boot. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Specifications > Page 6679 1. Install the inner gearshift lever boot. 1 Position the inner gearshift lever boot. 2 Install the bolts. 2. Install the gearshift lever. 1 Position the gearshift lever. 2 Install the bolt. 3. Install the screws. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Rail, M/T > Component Information > Specifications Shift Rail: Specifications Fifth/Reverse Shift Rail Bolt ...................................................................................................................................................... 20-30 Nm (15-22 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6688 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6689 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6690 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6691 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6692 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6693 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6694 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6695 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6696 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6697 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6698 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6699 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6700 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6701 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6702 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6703 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6704 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6705 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6706 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6707 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6708 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6709 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6710 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6711 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6712 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6713 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6714 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6715 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6716 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6717 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6718 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6719 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6720 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6721 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6722 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6723 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6724 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6725 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6726 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6727 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6728 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6729 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6730 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6731 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6732 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6733 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6734 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6735 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6736 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6737 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6738 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6739 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6740 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6741 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6742 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6743 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6744 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6745 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6746 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6747 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6748 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6749 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6750 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6751 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6752 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6753 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6754 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6755 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6756 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6757 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6758 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6759 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6760 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6761 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6762 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6763 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6764 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6765 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6766 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6767 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6768 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6769 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6770 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6771 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6772 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6773 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6774 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6775 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6776 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6777 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6778 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6779 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6780 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6781 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 6782 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T > Component Information > Technical Service Bulletins > Page 6783 Transmission Mount: Specifications Transmission Mount Bolts 87-110 Nm Transmission Mount Nuts 87-110 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Diagrams > Output Shaft Speed Sensor Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Diagrams > Output Shaft Speed Sensor > Page 6788 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 6789 Transmission Speed Sensor: Service and Repair Removal 1. Remove the drive shaft. 2. Remove the rear transmission mount nuts. 3. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the TSS and OSS sensors will occur. Remove the rear transmission mount. 1 Raise the transmission up off the rear crossmember support. 2 Remove the bolts. 3 Remove the rear transmission mount. 4. Lower the transmission to gain access to the Turbine Shaft Speed (TSS) sensor, and the Output Shaft Speed (OSS) sensor. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 6790 5. Remove the Turbine Shaft Sensor (TSS). 1 Remove the bolt. 2 Remove the Turbine Shaft Sensor (TSS). 6. Remove the Output Shaft Speed (OSS) sensor. 1 Remove the bolt. 2 Remove the Output Shaft Speed (OSS) sensor. Installation 1. Install the Output Shaft Speed (OSS) sensor. 1 Lubricate the O-ring and install the Output Shaft Speed (OSS) sensor. 2 Install the bolt. 2. Install the Turbine Shaft Sensor (TSS). 1 Lubricate the O-ring and install the Turbine Shaft Sensor (TSS). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 6791 2 Install the bolt. 3. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the sensors will occur. Install the rear transmission mount. 1 Raise the transmission up. 2 Install the rear transmission mount. 3 Install the bolts. 4. Lower the transmission on to the rear crossmember support. 5. Install the rear transmission mount nuts. 6. Install the drive shaft. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts Control Module: Customer Interest Transfer Case - Inadvertent Shifts Article No. 01-14-1 07/23/01 ^ ELECTRICAL - ELECTRONIC SHIFT ON THE FLY (ESOF) TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS ^ TRANSMISSION - TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS VEHICLES EQUIPPED WITH ELECTRONIC SHIFT ON THE FLY (ESOF) ONLY FORD: 1999 F-250 LD 1999-2001 EXPEDITION, F-150 LINCOLN: 1999-2001 NAVIGATOR ISSUE Some vehicles may exhibit inadvertent 4X4 Hi or Low shift events, 4X4 and/or Low Range indicator flashing or solid or vehicle stuck in 4L after uncommanded shift. This may be caused by the 4X4 shift motor. ACTION Install a YL1Z-7G360-AA shift motor on vehicles built before 12/99. The YL1Z-7G360-AA shift motor with a grey contact plate cover replaces the prior design F75Z-7G360-AA motor with a blue contact plate cover. Grey cover shift motors contain improved sense plate material and shift motor terminal upgrade. For vehicles already equipped with the latest style shift motor, refer to the following Service Procedure for details. SERVICE PROCEDURE For overall description and operation of the Electronic Shift On The Fly (ESOF) Transfer Case refer to Section 308-07 of the appropriate model year Workshop Manual. NOTE ALL DIAGNOSIS BY SYMPTOM SECTIONS HEREIN ARE WRITTEN ASSUMING THAT VEHICLE IS ALREADY EQUIPPED WITH THE LATEST STYLE SHIFT MOTOR. ALWAYS REPLACE SHIFT MOTOR AS A FIRST STEP IF CURRENT MOTOR IS PRIOR LEVEL WITH BLUE COVER. NOTE TO RESET THE GEM'S 4X4 MONITORING SOFTWARE, USE CLEAR DTC COMMAND IN THE NGS OR WOS TESTER (EVEN IF NO DTC'S ARE AVAILABLE) AND CYCLE IGNITION KEY ON-OFF-ON. RECORD ANY CONTINUOUS MEMORY CODES PRIOR TO CLEARING DTCs. NOTE AN UNCOMMANDED 4H OR 4L SHIFT DUE TO FALSE SHIFT MOTOR CONTACT PLATE SIGNAL MAY OR MAY NOT BE ACCOMPANIED BY SHIFT MOTOR DTC'S P1838, P1846, P1850, P1854, P1858, P1866, AND/OR P1867 STORED IN THE GEM DEPENDING ON WHETHER THE IGNITION KEY WAS CYCLED AFTER THE EVENT. NOTE CONTACT PLATE PIDS READ OPPOSITE OF 1999 OR EARLIER WORKSHOP MANUALS WHEN VIEWED WITH NGS RED CARD VERSIONS 15.0 OR LATER. THIS TSB CONTENT REFLECTS USING NGS VERSION 18.0. UNCOMMANDED SHIFT TO 4L 1. Parking Maneuvers/Gear Lever Transitions: Symptoms noted during a lower speed uncommanded shift to 4L event include: ^ Front end binding or hopping while turning ^ Bind feel in drivetrain when backing up and/or turning Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 6802 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 6803 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts Control Module: All Technical Service Bulletins Transfer Case - Inadvertent Shifts Article No. 01-14-1 07/23/01 ^ ELECTRICAL - ELECTRONIC SHIFT ON THE FLY (ESOF) TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS ^ TRANSMISSION - TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS VEHICLES EQUIPPED WITH ELECTRONIC SHIFT ON THE FLY (ESOF) ONLY FORD: 1999 F-250 LD 1999-2001 EXPEDITION, F-150 LINCOLN: 1999-2001 NAVIGATOR ISSUE Some vehicles may exhibit inadvertent 4X4 Hi or Low shift events, 4X4 and/or Low Range indicator flashing or solid or vehicle stuck in 4L after uncommanded shift. This may be caused by the 4X4 shift motor. ACTION Install a YL1Z-7G360-AA shift motor on vehicles built before 12/99. The YL1Z-7G360-AA shift motor with a grey contact plate cover replaces the prior design F75Z-7G360-AA motor with a blue contact plate cover. Grey cover shift motors contain improved sense plate material and shift motor terminal upgrade. For vehicles already equipped with the latest style shift motor, refer to the following Service Procedure for details. SERVICE PROCEDURE For overall description and operation of the Electronic Shift On The Fly (ESOF) Transfer Case refer to Section 308-07 of the appropriate model year Workshop Manual. NOTE ALL DIAGNOSIS BY SYMPTOM SECTIONS HEREIN ARE WRITTEN ASSUMING THAT VEHICLE IS ALREADY EQUIPPED WITH THE LATEST STYLE SHIFT MOTOR. ALWAYS REPLACE SHIFT MOTOR AS A FIRST STEP IF CURRENT MOTOR IS PRIOR LEVEL WITH BLUE COVER. NOTE TO RESET THE GEM'S 4X4 MONITORING SOFTWARE, USE CLEAR DTC COMMAND IN THE NGS OR WOS TESTER (EVEN IF NO DTC'S ARE AVAILABLE) AND CYCLE IGNITION KEY ON-OFF-ON. RECORD ANY CONTINUOUS MEMORY CODES PRIOR TO CLEARING DTCs. NOTE AN UNCOMMANDED 4H OR 4L SHIFT DUE TO FALSE SHIFT MOTOR CONTACT PLATE SIGNAL MAY OR MAY NOT BE ACCOMPANIED BY SHIFT MOTOR DTC'S P1838, P1846, P1850, P1854, P1858, P1866, AND/OR P1867 STORED IN THE GEM DEPENDING ON WHETHER THE IGNITION KEY WAS CYCLED AFTER THE EVENT. NOTE CONTACT PLATE PIDS READ OPPOSITE OF 1999 OR EARLIER WORKSHOP MANUALS WHEN VIEWED WITH NGS RED CARD VERSIONS 15.0 OR LATER. THIS TSB CONTENT REFLECTS USING NGS VERSION 18.0. UNCOMMANDED SHIFT TO 4L 1. Parking Maneuvers/Gear Lever Transitions: Symptoms noted during a lower speed uncommanded shift to 4L event include: ^ Front end binding or hopping while turning ^ Bind feel in drivetrain when backing up and/or turning Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 6809 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 6810 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 6811 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Shift on the Fly Relay Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Shift on the Fly Relay > Page 6816 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Page 6817 Four Wheel Drive Selector Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Page 6818 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Description and Operation Overdrive Switch: Description and Operation The Transmission Control Switch (TCS) is a momentary contact switch that is located on the end of the transmission control selector lever. Pushing the TCS will either disengage or engage the overdrive function of the transmission. if the OVERDRIVE is disengaged, the word OFF will illuminate on the transmission control selector lever. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Description and Operation > Page 6824 Overdrive Switch: Service and Repair Removal 1. Remove the Transmission Control Switch (TCS). 1 Remove the TCS cover. 2 Remove the TCS. Installation 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > 4R70W Transmission Position Switch/Sensor: Specifications Digital Transmission Range Sensor Bolts 7-10 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > 4R70W > Page 6829 Transmission Position Switch/Sensor: Specifications Digital Transmission TR Sensor 8-10 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 6830 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W Transmission Position Switch/Sensor: Service and Repair 4R70W Special Tools 1. Raise and support vehicle. 2. Disconnect the manual lever shift control cable. 3. Disconnect the digital TR electrical connector. 4. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. The old nut will not retain torque specification. Remove the manual control lever. 1 Remove the nut. 2 Remove the lever. 5. Loosen the digital TR sensor bolts. 6. NOTE: Manual shift lever must be in the neutral position. Use digital transmission range TR Sensor Alignment Tool, to align the digital TR sensor slots. The tool is designed to fit snug. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W > Page 6833 7. Tighten the bolts. 8. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual lever shaft outer nut. 9. With the manual lever in overdrive connect the shift lever control cable. 10. Install the digital TR sensor electrical connector. 11. Lower the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W > Page 6834 Transmission Position Switch/Sensor: Service and Repair 4R100 Special Tools Removal 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Disconnect the connector. 4. Disconnect the shift cable at the manual control lever. 5. Remove the digital Transmission Range (TR) sensor. 1 Remove the bolts. 2 Remove the digital Transmission Range (TR) sensor. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W > Page 6835 1. Install the digital Transmission Range (TR) sensor. 1 Install digital Transmission Range (TR) sensor. 2 Loosely install the bolts. 2. NOTE: Make sure that the manual control lever is in the neutral position. Install the Digital Transmission Range (TR) Sensor Alignment Tool. The tool is designed to fit snug. 3. Tighten the bolts. 4. Reconnect the shift cable at the manual control lever. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W > Page 6836 5. Reconnect the connector. 6. Lower the vehicle. 7. Reconnect the battery ground cable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Tools and Equipment > 4R70W Special Tool Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Tools and Equipment > 4R70W > Page 6839 Special Tool Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed Sensor Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed Sensor > Page 6844 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 6845 Transmission Speed Sensor: Service and Repair Removal 1. Remove the drive shaft. 2. Remove the rear transmission mount nuts. 3. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the TSS and OSS sensors will occur. Remove the rear transmission mount. 1 Raise the transmission up off the rear crossmember support. 2 Remove the bolts. 3 Remove the rear transmission mount. 4. Lower the transmission to gain access to the Turbine Shaft Speed (TSS) sensor, and the Output Shaft Speed (OSS) sensor. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 6846 5. Remove the Turbine Shaft Sensor (TSS). 1 Remove the bolt. 2 Remove the Turbine Shaft Sensor (TSS). 6. Remove the Output Shaft Speed (OSS) sensor. 1 Remove the bolt. 2 Remove the Output Shaft Speed (OSS) sensor. Installation 1. Install the Output Shaft Speed (OSS) sensor. 1 Lubricate the O-ring and install the Output Shaft Speed (OSS) sensor. 2 Install the bolt. 2. Install the Turbine Shaft Sensor (TSS). 1 Lubricate the O-ring and install the Turbine Shaft Sensor (TSS). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 6847 2 Install the bolt. 3. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the sensors will occur. Install the rear transmission mount. 1 Raise the transmission up. 2 Install the rear transmission mount. 3 Install the bolts. 4. Lower the transmission on to the rear crossmember support. 5. Install the rear transmission mount nuts. 6. Install the drive shaft. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Output Shaft Speed Sensor Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Output Shaft Speed Sensor > Page 6853 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 6854 Transmission Speed Sensor: Service and Repair Removal 1. Remove the drive shaft. 2. Remove the rear transmission mount nuts. 3. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the TSS and OSS sensors will occur. Remove the rear transmission mount. 1 Raise the transmission up off the rear crossmember support. 2 Remove the bolts. 3 Remove the rear transmission mount. 4. Lower the transmission to gain access to the Turbine Shaft Speed (TSS) sensor, and the Output Shaft Speed (OSS) sensor. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 6855 5. Remove the Turbine Shaft Sensor (TSS). 1 Remove the bolt. 2 Remove the Turbine Shaft Sensor (TSS). 6. Remove the Output Shaft Speed (OSS) sensor. 1 Remove the bolt. 2 Remove the Output Shaft Speed (OSS) sensor. Installation 1. Install the Output Shaft Speed (OSS) sensor. 1 Lubricate the O-ring and install the Output Shaft Speed (OSS) sensor. 2 Install the bolt. 2. Install the Turbine Shaft Sensor (TSS). 1 Lubricate the O-ring and install the Turbine Shaft Sensor (TSS). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 6856 2 Install the bolt. 3. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the sensors will occur. Install the rear transmission mount. 1 Raise the transmission up. 2 Install the rear transmission mount. 3 Install the bolts. 4. Lower the transmission on to the rear crossmember support. 5. Install the rear transmission mount nuts. 6. Install the drive shaft. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Specifications Four Wheel Drive Selector Switch: Specifications 4WD Indicator Switch .......................................................................................................................... ................................................ 41 Nm (30 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Specifications > Page 6861 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Specifications > Page 6862 Four Wheel Drive Selector Switch: Service and Repair Removal 1. Remove the center instrument panel trim plate. 2. Remove the shift range selector switch. 1 Remove the shift range selector switch knob. 2 Disconnect the shift range selector switch electrical connector. 3 Remove the two shift range selector switch bolts. 4 Remove the shift range selector switch. Installation 1. Install the shift range selector switch. 1 Position the shift range selector switch. 2 Install the bolts. 3 Install the electrical connector. 4 Install the knob. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Specifications > Page 6863 2. Install the center instrument panel trim plate. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Page 6867 Gear Sensor/Switch: Service and Repair Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the 4WD indicator switch. 1 Disconnect the 4WD indicator switch electrical connector. 2 Remove the 4WD indicator switch. Installation 1. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Specifications Speed Sensor: Specifications Output Shaft Speed Sensor 4 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Specifications > Page 6871 Speed Sensor: Service and Repair Removal 1. Remove the output shaft speed sensor connector. 2. Remove the bolt and the output shaft speed sensor. Installation 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications Transfer Case Actuator: Specifications Shift Motor Bolts .................................................................................................................................. ............................................. 10 Nm (89 inch lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 6877 Transfer Case Actuator: Service and Repair Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Disconnect the shift motor electrical connector. 3. Remove the coil wire from the electric shift motor electrical connector. 1 Remove the wire connector spacer. 2 Remove the coil wire and pin. Use correct electrical connector pin remover. 4. Remove the transfer case shift motor. 1 Remove the bolts. 2 Remove the transfer case shift motor. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 6878 1. Install the transfer case shift motor. 1 Position the transfer case shift motor. 2 Install the bolts. 2. Install the coil wire into the transfer case shift motor electrical connector. 1 Install the coil wire and pin. 2 Install the wire connector spacer. 3. Connect the transfer case shift motor electrical connector. 4. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts Case: Customer Interest Transfer Case - Inadvertent Shifts Article No. 01-14-1 07/23/01 ^ ELECTRICAL - ELECTRONIC SHIFT ON THE FLY (ESOF) TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS ^ TRANSMISSION - TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS VEHICLES EQUIPPED WITH ELECTRONIC SHIFT ON THE FLY (ESOF) ONLY FORD: 1999 F-250 LD 1999-2001 EXPEDITION, F-150 LINCOLN: 1999-2001 NAVIGATOR ISSUE Some vehicles may exhibit inadvertent 4X4 Hi or Low shift events, 4X4 and/or Low Range indicator flashing or solid or vehicle stuck in 4L after uncommanded shift. This may be caused by the 4X4 shift motor. ACTION Install a YL1Z-7G360-AA shift motor on vehicles built before 12/99. The YL1Z-7G360-AA shift motor with a grey contact plate cover replaces the prior design F75Z-7G360-AA motor with a blue contact plate cover. Grey cover shift motors contain improved sense plate material and shift motor terminal upgrade. For vehicles already equipped with the latest style shift motor, refer to the following Service Procedure for details. SERVICE PROCEDURE For overall description and operation of the Electronic Shift On The Fly (ESOF) Transfer Case refer to Section 308-07 of the appropriate model year Workshop Manual. NOTE ALL DIAGNOSIS BY SYMPTOM SECTIONS HEREIN ARE WRITTEN ASSUMING THAT VEHICLE IS ALREADY EQUIPPED WITH THE LATEST STYLE SHIFT MOTOR. ALWAYS REPLACE SHIFT MOTOR AS A FIRST STEP IF CURRENT MOTOR IS PRIOR LEVEL WITH BLUE COVER. NOTE TO RESET THE GEM'S 4X4 MONITORING SOFTWARE, USE CLEAR DTC COMMAND IN THE NGS OR WOS TESTER (EVEN IF NO DTC'S ARE AVAILABLE) AND CYCLE IGNITION KEY ON-OFF-ON. RECORD ANY CONTINUOUS MEMORY CODES PRIOR TO CLEARING DTCs. NOTE AN UNCOMMANDED 4H OR 4L SHIFT DUE TO FALSE SHIFT MOTOR CONTACT PLATE SIGNAL MAY OR MAY NOT BE ACCOMPANIED BY SHIFT MOTOR DTC'S P1838, P1846, P1850, P1854, P1858, P1866, AND/OR P1867 STORED IN THE GEM DEPENDING ON WHETHER THE IGNITION KEY WAS CYCLED AFTER THE EVENT. NOTE CONTACT PLATE PIDS READ OPPOSITE OF 1999 OR EARLIER WORKSHOP MANUALS WHEN VIEWED WITH NGS RED CARD VERSIONS 15.0 OR LATER. THIS TSB CONTENT REFLECTS USING NGS VERSION 18.0. UNCOMMANDED SHIFT TO 4L 1. Parking Maneuvers/Gear Lever Transitions: Symptoms noted during a lower speed uncommanded shift to 4L event include: ^ Front end binding or hopping while turning ^ Bind feel in drivetrain when backing up and/or turning Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 6887 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 6888 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts Case: All Technical Service Bulletins Transfer Case - Inadvertent Shifts Article No. 01-14-1 07/23/01 ^ ELECTRICAL - ELECTRONIC SHIFT ON THE FLY (ESOF) TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS ^ TRANSMISSION - TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS VEHICLES EQUIPPED WITH ELECTRONIC SHIFT ON THE FLY (ESOF) ONLY FORD: 1999 F-250 LD 1999-2001 EXPEDITION, F-150 LINCOLN: 1999-2001 NAVIGATOR ISSUE Some vehicles may exhibit inadvertent 4X4 Hi or Low shift events, 4X4 and/or Low Range indicator flashing or solid or vehicle stuck in 4L after uncommanded shift. This may be caused by the 4X4 shift motor. ACTION Install a YL1Z-7G360-AA shift motor on vehicles built before 12/99. The YL1Z-7G360-AA shift motor with a grey contact plate cover replaces the prior design F75Z-7G360-AA motor with a blue contact plate cover. Grey cover shift motors contain improved sense plate material and shift motor terminal upgrade. For vehicles already equipped with the latest style shift motor, refer to the following Service Procedure for details. SERVICE PROCEDURE For overall description and operation of the Electronic Shift On The Fly (ESOF) Transfer Case refer to Section 308-07 of the appropriate model year Workshop Manual. NOTE ALL DIAGNOSIS BY SYMPTOM SECTIONS HEREIN ARE WRITTEN ASSUMING THAT VEHICLE IS ALREADY EQUIPPED WITH THE LATEST STYLE SHIFT MOTOR. ALWAYS REPLACE SHIFT MOTOR AS A FIRST STEP IF CURRENT MOTOR IS PRIOR LEVEL WITH BLUE COVER. NOTE TO RESET THE GEM'S 4X4 MONITORING SOFTWARE, USE CLEAR DTC COMMAND IN THE NGS OR WOS TESTER (EVEN IF NO DTC'S ARE AVAILABLE) AND CYCLE IGNITION KEY ON-OFF-ON. RECORD ANY CONTINUOUS MEMORY CODES PRIOR TO CLEARING DTCs. NOTE AN UNCOMMANDED 4H OR 4L SHIFT DUE TO FALSE SHIFT MOTOR CONTACT PLATE SIGNAL MAY OR MAY NOT BE ACCOMPANIED BY SHIFT MOTOR DTC'S P1838, P1846, P1850, P1854, P1858, P1866, AND/OR P1867 STORED IN THE GEM DEPENDING ON WHETHER THE IGNITION KEY WAS CYCLED AFTER THE EVENT. NOTE CONTACT PLATE PIDS READ OPPOSITE OF 1999 OR EARLIER WORKSHOP MANUALS WHEN VIEWED WITH NGS RED CARD VERSIONS 15.0 OR LATER. THIS TSB CONTENT REFLECTS USING NGS VERSION 18.0. UNCOMMANDED SHIFT TO 4L 1. Parking Maneuvers/Gear Lever Transitions: Symptoms noted during a lower speed uncommanded shift to 4L event include: ^ Front end binding or hopping while turning ^ Bind feel in drivetrain when backing up and/or turning Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 6894 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 6895 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Case: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Fuel Filler Hose: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON Article No. 03-20-3 10/13/03 DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457 FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG, TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250 HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003 LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2003 MOUNTAINEER This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures. ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc. ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for details. Definitions of Acronyms ^ CVS Canister Vent Solenoid ^ DTC Diagnostic Trouble Code ^ EVAP Evaporative Emissions System ^ EVMV Electronic Vapor Management Valve ^ FTP Fuel Tank Pressure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Case: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 6901 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Case: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 6902 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Case: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 6903 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Case: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 6904 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Case: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 6905 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Case: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 6911 ^ MIL Malfunction Indicator Lamp ^ NGS New Generation STAR Tester ^ PID Parameter Identifier WDS Worldwide Diagnostic System SERVICE PROCEDURE NOTE THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE MANUALS AND TSB ARTICLES. NOTE MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE LEAK, CLEAN THE CAP AND REINSTALL. OVERVIEW OF TEST PROCEDURES Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Case: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 6912 NOTE SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART. This TSB provides the following procedures: ^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition ^ Locate a leak so that a repair can be performed Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Case: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 6913 ^ Verify repair by utilizing a metered air pressure test EVAP CANISTER PURGE VALVE NO FLOW TEST 1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP. 2. Start the vehicle. 3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP Canister Purge Valve (EVAPVM# Off or zero % duty cycle). 4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the EVAPVM# PID to 100% duty 5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve, verify the repair by repeating the No Flow Test and return vehicle. SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) 1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it at the EVAP Canister Purge Valve (see Figure 2). 2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should be on indicating a good battery contact. 3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE". 4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Case: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 6914 WARNING DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL PERMANENTLY DAMAGE THE VALVE. 5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine to EVAP Canister Purge Valve test port. NOTE SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD & PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM ENTERING THE FILLER NECK. 6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle. Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS, Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION). 8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15 seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are difficult to access, such as connections on top of the tank where connections may be or inside frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve. Go to LEAK VERIFICATION to verify any repair or if no leak is found. LEAK VERIFICATION (METERED AIR SYSTEM) 1. Position the selector valve located on the Smoke Machine control panel to "METER". 2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice located on the front of the Smoke Machine panel. 3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball. Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated leak orifice. NOTE THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Case: > 03-20-3 > Oct > 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 6915 4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter. 5. Use NGS or WDS Diagnostic tool to CLOSE the CVS. 6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to depress the remote starter button until the ball stops descending. Once the indicator ball has stopped descending, observe if it is above or below the red indicator flag. If performing this verification following a repair, go to Step 7. If performing this verification after performing the SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8. 7. Leak Verification After Repair a. If the measurement is below the indicator flag the system has passed. The test procedure is complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE) a. If the measurement is below the indicator flag the system has passed, go to Step 9. b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE). 9. Using WDS Datalogger or NGS select the FTPV PID. 10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV PID. 11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V, the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to Step 12.) 12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good working order and tightened. Repair as necessary. If no problem is found with clamps, replace the fuel cap. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS: INFORMATION ONLY Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Case, Transfer Case > Component Information > Technical Service Bulletins > Page 6916 Case: Specifications Transfer Case Extension Housing Bolts 24 Nm Transfer Case Skid Plate Bolts 15 Nm Transmission-To-Transfer Case Bolts 47 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case Inadvertent Shifts Control Module: Customer Interest Transfer Case - Inadvertent Shifts Article No. 01-14-1 07/23/01 ^ ELECTRICAL - ELECTRONIC SHIFT ON THE FLY (ESOF) TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS ^ TRANSMISSION - TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS VEHICLES EQUIPPED WITH ELECTRONIC SHIFT ON THE FLY (ESOF) ONLY FORD: 1999 F-250 LD 1999-2001 EXPEDITION, F-150 LINCOLN: 1999-2001 NAVIGATOR ISSUE Some vehicles may exhibit inadvertent 4X4 Hi or Low shift events, 4X4 and/or Low Range indicator flashing or solid or vehicle stuck in 4L after uncommanded shift. This may be caused by the 4X4 shift motor. ACTION Install a YL1Z-7G360-AA shift motor on vehicles built before 12/99. The YL1Z-7G360-AA shift motor with a grey contact plate cover replaces the prior design F75Z-7G360-AA motor with a blue contact plate cover. Grey cover shift motors contain improved sense plate material and shift motor terminal upgrade. For vehicles already equipped with the latest style shift motor, refer to the following Service Procedure for details. SERVICE PROCEDURE For overall description and operation of the Electronic Shift On The Fly (ESOF) Transfer Case refer to Section 308-07 of the appropriate model year Workshop Manual. NOTE ALL DIAGNOSIS BY SYMPTOM SECTIONS HEREIN ARE WRITTEN ASSUMING THAT VEHICLE IS ALREADY EQUIPPED WITH THE LATEST STYLE SHIFT MOTOR. ALWAYS REPLACE SHIFT MOTOR AS A FIRST STEP IF CURRENT MOTOR IS PRIOR LEVEL WITH BLUE COVER. NOTE TO RESET THE GEM'S 4X4 MONITORING SOFTWARE, USE CLEAR DTC COMMAND IN THE NGS OR WOS TESTER (EVEN IF NO DTC'S ARE AVAILABLE) AND CYCLE IGNITION KEY ON-OFF-ON. RECORD ANY CONTINUOUS MEMORY CODES PRIOR TO CLEARING DTCs. NOTE AN UNCOMMANDED 4H OR 4L SHIFT DUE TO FALSE SHIFT MOTOR CONTACT PLATE SIGNAL MAY OR MAY NOT BE ACCOMPANIED BY SHIFT MOTOR DTC'S P1838, P1846, P1850, P1854, P1858, P1866, AND/OR P1867 STORED IN THE GEM DEPENDING ON WHETHER THE IGNITION KEY WAS CYCLED AFTER THE EVENT. NOTE CONTACT PLATE PIDS READ OPPOSITE OF 1999 OR EARLIER WORKSHOP MANUALS WHEN VIEWED WITH NGS RED CARD VERSIONS 15.0 OR LATER. THIS TSB CONTENT REFLECTS USING NGS VERSION 18.0. UNCOMMANDED SHIFT TO 4L 1. Parking Maneuvers/Gear Lever Transitions: Symptoms noted during a lower speed uncommanded shift to 4L event include: ^ Front end binding or hopping while turning ^ Bind feel in drivetrain when backing up and/or turning Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case Inadvertent Shifts > Page 6925 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case Inadvertent Shifts > Page 6926 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts Control Module: All Technical Service Bulletins Transfer Case - Inadvertent Shifts Article No. 01-14-1 07/23/01 ^ ELECTRICAL - ELECTRONIC SHIFT ON THE FLY (ESOF) TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS ^ TRANSMISSION - TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS VEHICLES EQUIPPED WITH ELECTRONIC SHIFT ON THE FLY (ESOF) ONLY FORD: 1999 F-250 LD 1999-2001 EXPEDITION, F-150 LINCOLN: 1999-2001 NAVIGATOR ISSUE Some vehicles may exhibit inadvertent 4X4 Hi or Low shift events, 4X4 and/or Low Range indicator flashing or solid or vehicle stuck in 4L after uncommanded shift. This may be caused by the 4X4 shift motor. ACTION Install a YL1Z-7G360-AA shift motor on vehicles built before 12/99. The YL1Z-7G360-AA shift motor with a grey contact plate cover replaces the prior design F75Z-7G360-AA motor with a blue contact plate cover. Grey cover shift motors contain improved sense plate material and shift motor terminal upgrade. For vehicles already equipped with the latest style shift motor, refer to the following Service Procedure for details. SERVICE PROCEDURE For overall description and operation of the Electronic Shift On The Fly (ESOF) Transfer Case refer to Section 308-07 of the appropriate model year Workshop Manual. NOTE ALL DIAGNOSIS BY SYMPTOM SECTIONS HEREIN ARE WRITTEN ASSUMING THAT VEHICLE IS ALREADY EQUIPPED WITH THE LATEST STYLE SHIFT MOTOR. ALWAYS REPLACE SHIFT MOTOR AS A FIRST STEP IF CURRENT MOTOR IS PRIOR LEVEL WITH BLUE COVER. NOTE TO RESET THE GEM'S 4X4 MONITORING SOFTWARE, USE CLEAR DTC COMMAND IN THE NGS OR WOS TESTER (EVEN IF NO DTC'S ARE AVAILABLE) AND CYCLE IGNITION KEY ON-OFF-ON. RECORD ANY CONTINUOUS MEMORY CODES PRIOR TO CLEARING DTCs. NOTE AN UNCOMMANDED 4H OR 4L SHIFT DUE TO FALSE SHIFT MOTOR CONTACT PLATE SIGNAL MAY OR MAY NOT BE ACCOMPANIED BY SHIFT MOTOR DTC'S P1838, P1846, P1850, P1854, P1858, P1866, AND/OR P1867 STORED IN THE GEM DEPENDING ON WHETHER THE IGNITION KEY WAS CYCLED AFTER THE EVENT. NOTE CONTACT PLATE PIDS READ OPPOSITE OF 1999 OR EARLIER WORKSHOP MANUALS WHEN VIEWED WITH NGS RED CARD VERSIONS 15.0 OR LATER. THIS TSB CONTENT REFLECTS USING NGS VERSION 18.0. UNCOMMANDED SHIFT TO 4L 1. Parking Maneuvers/Gear Lever Transitions: Symptoms noted during a lower speed uncommanded shift to 4L event include: ^ Front end binding or hopping while turning ^ Bind feel in drivetrain when backing up and/or turning Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 6932 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 6933 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 6934 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications Capacity Transfer Case Fluid ............................................................................................................................. ...................................................................... 2.0 Qts Note: Fill to bottom of fill hole. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 6939 Fluid - Transfer Case: Fluid Type Specifications Transfer Case Fluid ............................................................................................................................. ............................................................ Mercon ATF. MERCON(R) automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Page 6940 Fluid - Transfer Case: Service Precautions DO NOT over fill transfer case beyond normal fluid level. Fluid foaming and damage may occur. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Page 6941 Fluid - Transfer Case: Service and Repair FLUID FILL 1. CAUTION: If the proper fill procedures are not followed, transfer case failure can result. NOTE: The fluid level should be just below the fill plug. Remove the fill plug from the rear of the transfer case and check the fill level. If the fluid is below the specified level, fill with Motorcraft MERCON Multi-Purpose Automatic Transmission Fluid XT-2-QDX or -DDX or equivalent MERCON fluid. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Four Wheel Drive Indicator Lamp: Customer Interest Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 6950 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Four Wheel Drive Indicator Lamp: All Technical Service Bulletins Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 6956 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > 4X4 High Indicator Four Wheel Drive Indicator Lamp: Description and Operation 4X4 High Indicator The 4X4 high indicator will be illuminated when the vehicle is in 4X4 high mode and the GEM sends a ground signal to the instrument cluster. The 4X4 high indicator will prove out when the ignition switch is placed in the START position and then in the RUN position. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > 4X4 High Indicator > Page 6959 Four Wheel Drive Indicator Lamp: Description and Operation Low Range Indicator The LOW RANGE indicator Will be illuminated when the vehicle is in 4X4 low and the Powertrain Control Module (PCM) sends a message to the instrument cluster via the SCP network. The low range indicator will prove out when the ignition switch is placed in the START position and then in the RUN position. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Page 6960 Four Wheel Drive Indicator Lamp: Testing and Inspection Refer to Instrument Panel/Testing and Inspection/Procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Shift on the Fly Relay Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Shift on the Fly Relay > Page 6965 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Page 6966 Four Wheel Drive Selector Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Page 6967 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Specifications Four Wheel Drive Selector Switch: Specifications 4WD Indicator Switch .......................................................................................................................... ................................................ 41 Nm (30 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Specifications > Page 6971 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Specifications > Page 6972 Four Wheel Drive Selector Switch: Service and Repair Removal 1. Remove the center instrument panel trim plate. 2. Remove the shift range selector switch. 1 Remove the shift range selector switch knob. 2 Disconnect the shift range selector switch electrical connector. 3 Remove the two shift range selector switch bolts. 4 Remove the shift range selector switch. Installation 1. Install the shift range selector switch. 1 Position the shift range selector switch. 2 Install the bolts. 3 Install the electrical connector. 4 Install the knob. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component Information > Specifications > Page 6973 2. Install the center instrument panel trim plate. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Page 6977 Gear Sensor/Switch: Service and Repair Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the 4WD indicator switch. 1 Disconnect the 4WD indicator switch electrical connector. 2 Remove the 4WD indicator switch. Installation 1. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Four Wheel Drive Indicator Lamp: Customer Interest Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 6987 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Four Wheel Drive Indicator Lamp: All Technical Service Bulletins Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 6993 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > 4X4 High Indicator Four Wheel Drive Indicator Lamp: Description and Operation 4X4 High Indicator The 4X4 high indicator will be illuminated when the vehicle is in 4X4 high mode and the GEM sends a ground signal to the instrument cluster. The 4X4 high indicator will prove out when the ignition switch is placed in the START position and then in the RUN position. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > 4X4 High Indicator > Page 6996 Four Wheel Drive Indicator Lamp: Description and Operation Low Range Indicator The LOW RANGE indicator Will be illuminated when the vehicle is in 4X4 low and the Powertrain Control Module (PCM) sends a message to the instrument cluster via the SCP network. The low range indicator will prove out when the ignition switch is placed in the START position and then in the RUN position. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Page 6997 Four Wheel Drive Indicator Lamp: Testing and Inspection Refer to Instrument Panel/Testing and Inspection/Procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts Control Module: Customer Interest Transfer Case - Inadvertent Shifts Article No. 01-14-1 07/23/01 ^ ELECTRICAL - ELECTRONIC SHIFT ON THE FLY (ESOF) TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS ^ TRANSMISSION - TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS VEHICLES EQUIPPED WITH ELECTRONIC SHIFT ON THE FLY (ESOF) ONLY FORD: 1999 F-250 LD 1999-2001 EXPEDITION, F-150 LINCOLN: 1999-2001 NAVIGATOR ISSUE Some vehicles may exhibit inadvertent 4X4 Hi or Low shift events, 4X4 and/or Low Range indicator flashing or solid or vehicle stuck in 4L after uncommanded shift. This may be caused by the 4X4 shift motor. ACTION Install a YL1Z-7G360-AA shift motor on vehicles built before 12/99. The YL1Z-7G360-AA shift motor with a grey contact plate cover replaces the prior design F75Z-7G360-AA motor with a blue contact plate cover. Grey cover shift motors contain improved sense plate material and shift motor terminal upgrade. For vehicles already equipped with the latest style shift motor, refer to the following Service Procedure for details. SERVICE PROCEDURE For overall description and operation of the Electronic Shift On The Fly (ESOF) Transfer Case refer to Section 308-07 of the appropriate model year Workshop Manual. NOTE ALL DIAGNOSIS BY SYMPTOM SECTIONS HEREIN ARE WRITTEN ASSUMING THAT VEHICLE IS ALREADY EQUIPPED WITH THE LATEST STYLE SHIFT MOTOR. ALWAYS REPLACE SHIFT MOTOR AS A FIRST STEP IF CURRENT MOTOR IS PRIOR LEVEL WITH BLUE COVER. NOTE TO RESET THE GEM'S 4X4 MONITORING SOFTWARE, USE CLEAR DTC COMMAND IN THE NGS OR WOS TESTER (EVEN IF NO DTC'S ARE AVAILABLE) AND CYCLE IGNITION KEY ON-OFF-ON. RECORD ANY CONTINUOUS MEMORY CODES PRIOR TO CLEARING DTCs. NOTE AN UNCOMMANDED 4H OR 4L SHIFT DUE TO FALSE SHIFT MOTOR CONTACT PLATE SIGNAL MAY OR MAY NOT BE ACCOMPANIED BY SHIFT MOTOR DTC'S P1838, P1846, P1850, P1854, P1858, P1866, AND/OR P1867 STORED IN THE GEM DEPENDING ON WHETHER THE IGNITION KEY WAS CYCLED AFTER THE EVENT. NOTE CONTACT PLATE PIDS READ OPPOSITE OF 1999 OR EARLIER WORKSHOP MANUALS WHEN VIEWED WITH NGS RED CARD VERSIONS 15.0 OR LATER. THIS TSB CONTENT REFLECTS USING NGS VERSION 18.0. UNCOMMANDED SHIFT TO 4L 1. Parking Maneuvers/Gear Lever Transitions: Symptoms noted during a lower speed uncommanded shift to 4L event include: ^ Front end binding or hopping while turning ^ Bind feel in drivetrain when backing up and/or turning Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 7007 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 7008 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts Control Module: All Technical Service Bulletins Transfer Case - Inadvertent Shifts Article No. 01-14-1 07/23/01 ^ ELECTRICAL - ELECTRONIC SHIFT ON THE FLY (ESOF) TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS ^ TRANSMISSION - TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS VEHICLES EQUIPPED WITH ELECTRONIC SHIFT ON THE FLY (ESOF) ONLY FORD: 1999 F-250 LD 1999-2001 EXPEDITION, F-150 LINCOLN: 1999-2001 NAVIGATOR ISSUE Some vehicles may exhibit inadvertent 4X4 Hi or Low shift events, 4X4 and/or Low Range indicator flashing or solid or vehicle stuck in 4L after uncommanded shift. This may be caused by the 4X4 shift motor. ACTION Install a YL1Z-7G360-AA shift motor on vehicles built before 12/99. The YL1Z-7G360-AA shift motor with a grey contact plate cover replaces the prior design F75Z-7G360-AA motor with a blue contact plate cover. Grey cover shift motors contain improved sense plate material and shift motor terminal upgrade. For vehicles already equipped with the latest style shift motor, refer to the following Service Procedure for details. SERVICE PROCEDURE For overall description and operation of the Electronic Shift On The Fly (ESOF) Transfer Case refer to Section 308-07 of the appropriate model year Workshop Manual. NOTE ALL DIAGNOSIS BY SYMPTOM SECTIONS HEREIN ARE WRITTEN ASSUMING THAT VEHICLE IS ALREADY EQUIPPED WITH THE LATEST STYLE SHIFT MOTOR. ALWAYS REPLACE SHIFT MOTOR AS A FIRST STEP IF CURRENT MOTOR IS PRIOR LEVEL WITH BLUE COVER. NOTE TO RESET THE GEM'S 4X4 MONITORING SOFTWARE, USE CLEAR DTC COMMAND IN THE NGS OR WOS TESTER (EVEN IF NO DTC'S ARE AVAILABLE) AND CYCLE IGNITION KEY ON-OFF-ON. RECORD ANY CONTINUOUS MEMORY CODES PRIOR TO CLEARING DTCs. NOTE AN UNCOMMANDED 4H OR 4L SHIFT DUE TO FALSE SHIFT MOTOR CONTACT PLATE SIGNAL MAY OR MAY NOT BE ACCOMPANIED BY SHIFT MOTOR DTC'S P1838, P1846, P1850, P1854, P1858, P1866, AND/OR P1867 STORED IN THE GEM DEPENDING ON WHETHER THE IGNITION KEY WAS CYCLED AFTER THE EVENT. NOTE CONTACT PLATE PIDS READ OPPOSITE OF 1999 OR EARLIER WORKSHOP MANUALS WHEN VIEWED WITH NGS RED CARD VERSIONS 15.0 OR LATER. THIS TSB CONTENT REFLECTS USING NGS VERSION 18.0. UNCOMMANDED SHIFT TO 4L 1. Parking Maneuvers/Gear Lever Transitions: Symptoms noted during a lower speed uncommanded shift to 4L event include: ^ Front end binding or hopping while turning ^ Bind feel in drivetrain when backing up and/or turning Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 7014 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 7015 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 7016 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Shift on the Fly Relay Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Shift on the Fly Relay > Page 7021 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Page 7022 Four Wheel Drive Selector Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Page 7023 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair Seals and Gaskets: Service and Repair Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. Raise and support vehicle. 2. NOTE: Index-mark the rear driveshaft yoke and pinion flange to maintain initial driveshaft balance during installation. Remove the rear driveshaft. 3. Using a suitable tool, remove the oil seal. Installation 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Page 7027 - Using the special tool, install the oil seal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System Information > Service and Repair > Page 7028 Special Tool Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Specifications Four Wheel Drive Selector Switch: Specifications 4WD Indicator Switch .......................................................................................................................... ................................................ 41 Nm (30 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Specifications > Page 7033 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Specifications > Page 7034 Four Wheel Drive Selector Switch: Service and Repair Removal 1. Remove the center instrument panel trim plate. 2. Remove the shift range selector switch. 1 Remove the shift range selector switch knob. 2 Disconnect the shift range selector switch electrical connector. 3 Remove the two shift range selector switch bolts. 4 Remove the shift range selector switch. Installation 1. Install the shift range selector switch. 1 Position the shift range selector switch. 2 Install the bolts. 3 Install the electrical connector. 4 Install the knob. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Specifications > Page 7035 2. Install the center instrument panel trim plate. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Page 7039 Gear Sensor/Switch: Service and Repair Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the 4WD indicator switch. 1 Disconnect the 4WD indicator switch electrical connector. 2 Remove the 4WD indicator switch. Installation 1. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Specifications Speed Sensor: Specifications Output Shaft Speed Sensor 4 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Specifications > Page 7043 Speed Sensor: Service and Repair Removal 1. Remove the output shaft speed sensor connector. 2. Remove the bolt and the output shaft speed sensor. Installation 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information > Specifications Shifter Transfer Case: Specifications Shift Lever Boot Screws ............................................................................................................................................................. 5-9 Nm (44-80 inch lbs.) Shift Lever Cover Plate Bolts ............................................................................................................................................... 10-14 Nm (88-124 inch lbs.) Transfer Case Shift Lever Set Screw ...................................................................................................................................................... 10 Nm (7 ft. lbs.) Gearshift Lever Bolt To Transmission Bolts ........................................................................................................................... 98-132 Nm (72-97 ft. lbs.) Gearshift Lever-To-Shift Handle Bolts ...................................................................................................................................... 23-32 Nm (17-24 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information > Specifications > Page 7047 Shifter Transfer Case: Service and Repair Special Tools Removal 1. Remove the gearshift lever boot. 1 Remove the gearshift lever knob. 2 Remove the four gearshift lever boot screws. 3 Remove the gearshift lever boot. 2. Remove the gearshift lever cover. 1 Remove the four gearshift lever cover bolts. 2 Remove the gearshift lever cover. 3. Remove the upper gearshift lever. 1 Remove the upper gearshift lever bolt. 2 Remove the upper gearshift lever. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information > Specifications > Page 7048 4. Remove the lower gearshift lever. 1 Use the Shift Linkage Insulator Tool to disconnect the lower gearshift lever to transfer case rod. 2 Remove the two lower gearshift lever bolts. 3 Remove the lower gearshift lever. Installation 1. Install the lower gearshift lever. 1 Position the lower gearshift lever. 2 Install the two lower gearshift lever bolts. 3 Use the Shift Linkage Insulator Tool to connect the lower gearshift lever to transfer case rod. 2. Install the upper gearshift lever. 1 Position the upper gearshift lever. 2 Install the upper gearshift lever bolt. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information > Specifications > Page 7049 3. Install the gearshift lever cover. 1 Position the gearshift lever cover. 2 Install the four gearshift lever cover bolts. 4. Install the gearshift lever boot. 1 Position the gearshift lever boot. 2 Install the four gearshift lever boot screws. 3 Install the gearshift lever knob. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information > Specifications > Page 7050 Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Specifications Speed Sensor: Specifications Output Shaft Speed Sensor 4 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Speed Sensor, Transfer Case > Component Information > Specifications > Page 7054 Speed Sensor: Service and Repair Removal 1. Remove the output shaft speed sensor connector. 2. Remove the bolt and the output shaft speed sensor. Installation 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Specifications Transfer Case Actuator: Specifications Shift Motor Bolts .................................................................................................................................. ............................................. 10 Nm (89 inch lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 7058 Transfer Case Actuator: Service and Repair Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Disconnect the shift motor electrical connector. 3. Remove the coil wire from the electric shift motor electrical connector. 1 Remove the wire connector spacer. 2 Remove the coil wire and pin. Use correct electrical connector pin remover. 4. Remove the transfer case shift motor. 1 Remove the bolts. 2 Remove the transfer case shift motor. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 7059 1. Install the transfer case shift motor. 1 Position the transfer case shift motor. 2 Install the bolts. 2. Install the coil wire into the transfer case shift motor electrical connector. 1 Install the coil wire and pin. 2 Install the wire connector spacer. 3. Connect the transfer case shift motor electrical connector. 4. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Cover > Component Information > Specifications Transfer Case Cover: Specifications Cover-to-case bolts 24 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair Pressure Regulating Solenoid: Service and Repair Electronic Pressure Control (EPC) Solenoid Removal 1. Remove the manual control lever. 2. CAUTION: Do not pull on the plastic lead frame. This may cause damage to the connector ends. Carefully pry up on the locking tabs to disconnect the solenoids. Disconnect the molded lead frame from the solenoids. Disconnect the molded lead frame from the solenoids. 1 Disconnect the shift solenoid SSA and SSB. 2 Disconnect the Torque Converter Clutch (TCC). 3 Disconnect the Electronic Pressure Control (EPC) solenoid. 4 Disconnect the bulkhead inter-connector. 3. Remove the EPC solenoid. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Service and Repair > Page 7069 1. Install the EPC solenoid. 2. Connect the molded lead frame to the solenoids. - Connect the bulkhead inter-connector. - Connect the Electronic Pressure Control (EPC) solenoid. - Connect the Torque Converter Clutch (TCC). - Connect the shift solenoid SSA and SSB. 3. Install the manual control lever. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications Shift Interlock Solenoid: Specifications Shift Lock Actuator Bolts 7-11 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 7073 Shift Interlock Solenoid: Service and Repair Removal 1. Remove the steering column assembly. 2. Remove the insert plate and shift lock actuator. 1 Remove the bolts. 2 Remove the insert plate and shift lock actuator. 3. NOTE: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to be replaced in the field. Remove the insert plate from the shift lock actuator. Remove and discard the shift lock actuator clip. Installation 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair Shift Solenoid: Service and Repair Refer to Valve Body for service procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications Torque Converter Clutch Solenoid: Specifications TCC Solenoid Bolt 9-11 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications Transfer Case Actuator: Specifications Shift Motor Bolts .................................................................................................................................. ............................................. 10 Nm (89 inch lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 7084 Transfer Case Actuator: Service and Repair Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Disconnect the shift motor electrical connector. 3. Remove the coil wire from the electric shift motor electrical connector. 1 Remove the wire connector spacer. 2 Remove the coil wire and pin. Use correct electrical connector pin remover. 4. Remove the transfer case shift motor. 1 Remove the bolts. 2 Remove the transfer case shift motor. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications > Page 7085 1. Install the transfer case shift motor. 1 Position the transfer case shift motor. 2 Install the bolts. 2. Install the coil wire into the transfer case shift motor electrical connector. 1 Install the coil wire and pin. 2 Install the wire connector spacer. 3. Connect the transfer case shift motor electrical connector. 4. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Adjustments Shift Indicator: Adjustments 1. Remove the upper instrument panel steering column cover. 2. Place the gearshift lever in the (D) position. - Rotate the gearshift lever clockwise until it bottoms out (first gear), then rotate two detents counterclockwise (D) position). 3. Hang an eight pound weight on the gearshift lever. 4. Center the pointer in the middle of the (D) position. - Rotate the thumb wheel located on the bottom of the steering column to adjust the pointer. 5. Remove the eight pound weight. 6. Carefully move the gearshift lever from detent to detent and compare with transmission settings. Readjust if necessary. 7. Install the upper instrument panel steering column cover. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Four Wheel Drive Indicator Lamp: Customer Interest Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 7100 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Four Wheel Drive Indicator Lamp: All Technical Service Bulletins Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Four Wheel Drive Indicator Lamp: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 7106 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > 4X4 High Indicator Four Wheel Drive Indicator Lamp: Description and Operation 4X4 High Indicator The 4X4 high indicator will be illuminated when the vehicle is in 4X4 high mode and the GEM sends a ground signal to the instrument cluster. The 4X4 high indicator will prove out when the ignition switch is placed in the START position and then in the RUN position. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > 4X4 High Indicator > Page 7109 Four Wheel Drive Indicator Lamp: Description and Operation Low Range Indicator The LOW RANGE indicator Will be illuminated when the vehicle is in 4X4 low and the Powertrain Control Module (PCM) sends a message to the instrument cluster via the SCP network. The low range indicator will prove out when the ignition switch is placed in the START position and then in the RUN position. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Page 7110 Four Wheel Drive Indicator Lamp: Testing and Inspection Refer to Instrument Panel/Testing and Inspection/Procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case Inadvertent Shifts Control Module: Customer Interest Transfer Case - Inadvertent Shifts Article No. 01-14-1 07/23/01 ^ ELECTRICAL - ELECTRONIC SHIFT ON THE FLY (ESOF) TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS ^ TRANSMISSION - TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS VEHICLES EQUIPPED WITH ELECTRONIC SHIFT ON THE FLY (ESOF) ONLY FORD: 1999 F-250 LD 1999-2001 EXPEDITION, F-150 LINCOLN: 1999-2001 NAVIGATOR ISSUE Some vehicles may exhibit inadvertent 4X4 Hi or Low shift events, 4X4 and/or Low Range indicator flashing or solid or vehicle stuck in 4L after uncommanded shift. This may be caused by the 4X4 shift motor. ACTION Install a YL1Z-7G360-AA shift motor on vehicles built before 12/99. The YL1Z-7G360-AA shift motor with a grey contact plate cover replaces the prior design F75Z-7G360-AA motor with a blue contact plate cover. Grey cover shift motors contain improved sense plate material and shift motor terminal upgrade. For vehicles already equipped with the latest style shift motor, refer to the following Service Procedure for details. SERVICE PROCEDURE For overall description and operation of the Electronic Shift On The Fly (ESOF) Transfer Case refer to Section 308-07 of the appropriate model year Workshop Manual. NOTE ALL DIAGNOSIS BY SYMPTOM SECTIONS HEREIN ARE WRITTEN ASSUMING THAT VEHICLE IS ALREADY EQUIPPED WITH THE LATEST STYLE SHIFT MOTOR. ALWAYS REPLACE SHIFT MOTOR AS A FIRST STEP IF CURRENT MOTOR IS PRIOR LEVEL WITH BLUE COVER. NOTE TO RESET THE GEM'S 4X4 MONITORING SOFTWARE, USE CLEAR DTC COMMAND IN THE NGS OR WOS TESTER (EVEN IF NO DTC'S ARE AVAILABLE) AND CYCLE IGNITION KEY ON-OFF-ON. RECORD ANY CONTINUOUS MEMORY CODES PRIOR TO CLEARING DTCs. NOTE AN UNCOMMANDED 4H OR 4L SHIFT DUE TO FALSE SHIFT MOTOR CONTACT PLATE SIGNAL MAY OR MAY NOT BE ACCOMPANIED BY SHIFT MOTOR DTC'S P1838, P1846, P1850, P1854, P1858, P1866, AND/OR P1867 STORED IN THE GEM DEPENDING ON WHETHER THE IGNITION KEY WAS CYCLED AFTER THE EVENT. NOTE CONTACT PLATE PIDS READ OPPOSITE OF 1999 OR EARLIER WORKSHOP MANUALS WHEN VIEWED WITH NGS RED CARD VERSIONS 15.0 OR LATER. THIS TSB CONTENT REFLECTS USING NGS VERSION 18.0. UNCOMMANDED SHIFT TO 4L 1. Parking Maneuvers/Gear Lever Transitions: Symptoms noted during a lower speed uncommanded shift to 4L event include: ^ Front end binding or hopping while turning ^ Bind feel in drivetrain when backing up and/or turning Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case Inadvertent Shifts > Page 7121 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 01-14-1 > Jul > 01 > Transfer Case Inadvertent Shifts > Page 7122 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts Control Module: All Technical Service Bulletins Transfer Case - Inadvertent Shifts Article No. 01-14-1 07/23/01 ^ ELECTRICAL - ELECTRONIC SHIFT ON THE FLY (ESOF) TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS ^ TRANSMISSION - TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS VEHICLES EQUIPPED WITH ELECTRONIC SHIFT ON THE FLY (ESOF) ONLY FORD: 1999 F-250 LD 1999-2001 EXPEDITION, F-150 LINCOLN: 1999-2001 NAVIGATOR ISSUE Some vehicles may exhibit inadvertent 4X4 Hi or Low shift events, 4X4 and/or Low Range indicator flashing or solid or vehicle stuck in 4L after uncommanded shift. This may be caused by the 4X4 shift motor. ACTION Install a YL1Z-7G360-AA shift motor on vehicles built before 12/99. The YL1Z-7G360-AA shift motor with a grey contact plate cover replaces the prior design F75Z-7G360-AA motor with a blue contact plate cover. Grey cover shift motors contain improved sense plate material and shift motor terminal upgrade. For vehicles already equipped with the latest style shift motor, refer to the following Service Procedure for details. SERVICE PROCEDURE For overall description and operation of the Electronic Shift On The Fly (ESOF) Transfer Case refer to Section 308-07 of the appropriate model year Workshop Manual. NOTE ALL DIAGNOSIS BY SYMPTOM SECTIONS HEREIN ARE WRITTEN ASSUMING THAT VEHICLE IS ALREADY EQUIPPED WITH THE LATEST STYLE SHIFT MOTOR. ALWAYS REPLACE SHIFT MOTOR AS A FIRST STEP IF CURRENT MOTOR IS PRIOR LEVEL WITH BLUE COVER. NOTE TO RESET THE GEM'S 4X4 MONITORING SOFTWARE, USE CLEAR DTC COMMAND IN THE NGS OR WOS TESTER (EVEN IF NO DTC'S ARE AVAILABLE) AND CYCLE IGNITION KEY ON-OFF-ON. RECORD ANY CONTINUOUS MEMORY CODES PRIOR TO CLEARING DTCs. NOTE AN UNCOMMANDED 4H OR 4L SHIFT DUE TO FALSE SHIFT MOTOR CONTACT PLATE SIGNAL MAY OR MAY NOT BE ACCOMPANIED BY SHIFT MOTOR DTC'S P1838, P1846, P1850, P1854, P1858, P1866, AND/OR P1867 STORED IN THE GEM DEPENDING ON WHETHER THE IGNITION KEY WAS CYCLED AFTER THE EVENT. NOTE CONTACT PLATE PIDS READ OPPOSITE OF 1999 OR EARLIER WORKSHOP MANUALS WHEN VIEWED WITH NGS RED CARD VERSIONS 15.0 OR LATER. THIS TSB CONTENT REFLECTS USING NGS VERSION 18.0. UNCOMMANDED SHIFT TO 4L 1. Parking Maneuvers/Gear Lever Transitions: Symptoms noted during a lower speed uncommanded shift to 4L event include: ^ Front end binding or hopping while turning ^ Bind feel in drivetrain when backing up and/or turning Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 7128 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 7129 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information > Technical Service Bulletins > Page 7130 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Shift on the Fly Relay Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Shift on the Fly Relay > Page 7135 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Page 7136 Four Wheel Drive Selector Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Page 7137 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Description and Operation Overdrive Switch: Description and Operation The Transmission Control Switch (TCS) is a momentary contact switch that is located on the end of the transmission control selector lever. Pushing the TCS will either disengage or engage the overdrive function of the transmission. if the OVERDRIVE is disengaged, the word OFF will illuminate on the transmission control selector lever. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Overdrive Switch, A/T > Component Information > Description and Operation > Page 7143 Overdrive Switch: Service and Repair Removal 1. Remove the Transmission Control Switch (TCS). 1 Remove the TCS cover. 2 Remove the TCS. Installation 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > 4R70W Transmission Position Switch/Sensor: Specifications Digital Transmission Range Sensor Bolts 7-10 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > 4R70W > Page 7148 Transmission Position Switch/Sensor: Specifications Digital Transmission TR Sensor 8-10 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Specifications > Page 7149 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W Transmission Position Switch/Sensor: Service and Repair 4R70W Special Tools 1. Raise and support vehicle. 2. Disconnect the manual lever shift control cable. 3. Disconnect the digital TR electrical connector. 4. CAUTION: Discard outer manual control lever shaft nut. Do not reuse. The old nut will not retain torque specification. Remove the manual control lever. 1 Remove the nut. 2 Remove the lever. 5. Loosen the digital TR sensor bolts. 6. NOTE: Manual shift lever must be in the neutral position. Use digital transmission range TR Sensor Alignment Tool, to align the digital TR sensor slots. The tool is designed to fit snug. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W > Page 7152 7. Tighten the bolts. 8. Install the manual control lever. 1 Position the manual control lever. 2 Install a new manual lever shaft outer nut. 9. With the manual lever in overdrive connect the shift lever control cable. 10. Install the digital TR sensor electrical connector. 11. Lower the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W > Page 7153 Transmission Position Switch/Sensor: Service and Repair 4R100 Special Tools Removal 1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist. 3. Disconnect the connector. 4. Disconnect the shift cable at the manual control lever. 5. Remove the digital Transmission Range (TR) sensor. 1 Remove the bolts. 2 Remove the digital Transmission Range (TR) sensor. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W > Page 7154 1. Install the digital Transmission Range (TR) sensor. 1 Install digital Transmission Range (TR) sensor. 2 Loosely install the bolts. 2. NOTE: Make sure that the manual control lever is in the neutral position. Install the Digital Transmission Range (TR) Sensor Alignment Tool. The tool is designed to fit snug. 3. Tighten the bolts. 4. Reconnect the shift cable at the manual control lever. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Service and Repair > 4R70W > Page 7155 5. Reconnect the connector. 6. Lower the vehicle. 7. Reconnect the battery ground cable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Tools and Equipment > 4R70W Special Tool Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Tools and Equipment > 4R70W > Page 7158 Special Tool Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed Sensor Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Output Shaft Speed Sensor > Page 7163 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 7164 Transmission Speed Sensor: Service and Repair Removal 1. Remove the drive shaft. 2. Remove the rear transmission mount nuts. 3. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the TSS and OSS sensors will occur. Remove the rear transmission mount. 1 Raise the transmission up off the rear crossmember support. 2 Remove the bolts. 3 Remove the rear transmission mount. 4. Lower the transmission to gain access to the Turbine Shaft Speed (TSS) sensor, and the Output Shaft Speed (OSS) sensor. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 7165 5. Remove the Turbine Shaft Sensor (TSS). 1 Remove the bolt. 2 Remove the Turbine Shaft Sensor (TSS). 6. Remove the Output Shaft Speed (OSS) sensor. 1 Remove the bolt. 2 Remove the Output Shaft Speed (OSS) sensor. Installation 1. Install the Output Shaft Speed (OSS) sensor. 1 Lubricate the O-ring and install the Output Shaft Speed (OSS) sensor. 2 Install the bolt. 2. Install the Turbine Shaft Sensor (TSS). 1 Lubricate the O-ring and install the Turbine Shaft Sensor (TSS). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 7166 2 Install the bolt. 3. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the sensors will occur. Install the rear transmission mount. 1 Raise the transmission up. 2 Install the rear transmission mount. 3 Install the bolts. 4. Lower the transmission on to the rear crossmember support. 5. Install the rear transmission mount nuts. 6. Install the drive shaft. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Output Shaft Speed Sensor Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Output Shaft Speed Sensor > Page 7172 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 7173 Transmission Speed Sensor: Service and Repair Removal 1. Remove the drive shaft. 2. Remove the rear transmission mount nuts. 3. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the TSS and OSS sensors will occur. Remove the rear transmission mount. 1 Raise the transmission up off the rear crossmember support. 2 Remove the bolts. 3 Remove the rear transmission mount. 4. Lower the transmission to gain access to the Turbine Shaft Speed (TSS) sensor, and the Output Shaft Speed (OSS) sensor. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 7174 5. Remove the Turbine Shaft Sensor (TSS). 1 Remove the bolt. 2 Remove the Turbine Shaft Sensor (TSS). 6. Remove the Output Shaft Speed (OSS) sensor. 1 Remove the bolt. 2 Remove the Output Shaft Speed (OSS) sensor. Installation 1. Install the Output Shaft Speed (OSS) sensor. 1 Lubricate the O-ring and install the Output Shaft Speed (OSS) sensor. 2 Install the bolt. 2. Install the Turbine Shaft Sensor (TSS). 1 Lubricate the O-ring and install the Turbine Shaft Sensor (TSS). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 7175 2 Install the bolt. 3. CAUTION: Be sure not to raise the back of the transmission too high, if it makes contact with the underbody, damage to the sensors will occur. Install the rear transmission mount. 1 Raise the transmission up. 2 Install the rear transmission mount. 3 Install the bolts. 4. Lower the transmission on to the rear crossmember support. 5. Install the rear transmission mount nuts. 6. Install the drive shaft. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Specifications Four Wheel Drive Selector Switch: Specifications 4WD Indicator Switch .......................................................................................................................... ................................................ 41 Nm (30 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Specifications > Page 7180 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Specifications > Page 7181 Four Wheel Drive Selector Switch: Service and Repair Removal 1. Remove the center instrument panel trim plate. 2. Remove the shift range selector switch. 1 Remove the shift range selector switch knob. 2 Disconnect the shift range selector switch electrical connector. 3 Remove the two shift range selector switch bolts. 4 Remove the shift range selector switch. Installation 1. Install the shift range selector switch. 1 Position the shift range selector switch. 2 Install the bolts. 3 Install the electrical connector. 4 Install the knob. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Specifications > Page 7182 2. Install the center instrument panel trim plate. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Gear Sensor/Switch, Transfer Case > Component Information > Diagrams > Page 7186 Gear Sensor/Switch: Service and Repair Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the 4WD indicator switch. 1 Disconnect the 4WD indicator switch electrical connector. 2 Remove the 4WD indicator switch. Installation 1. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Specifications Speed Sensor: Specifications Output Shaft Speed Sensor 4 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Speed Sensor, Transfer Case > Component Information > Specifications > Page 7190 Speed Sensor: Service and Repair Removal 1. Remove the output shaft speed sensor connector. 2. Remove the bolt and the output shaft speed sensor. Installation 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Locations Diagnostic Connector - ABS: Locations NOTE: There are TWO diagnostic test connectors in this system. Ford uses varying terminology for these connectors but you can identify them by connector number and by location. - The first test connector is the black RABS Diagnostic Test Connector C207. This primary test connector is used to retrieve and clear codes. RABS Data Link Connector Location RABS Data Link Connector C207 is located behind the right side of the Instrument Panel. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic Connector - ABS > Component Information > Locations > Page 7196 - The second test connector is the Differential Speed Sensor (DSS) Data Link Connector (DLC) C268. This connector is used only when instructed to by a procedure in a pinpoint test. The Differential Speed Sensor (DSS) Data Link Connector (DLC) C268 is located to the left side of the Central Junction Box. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Specifications Electronic Brake Control Module: Specifications TORQUE SPECIFICATIONS Rear Wheel Anti-Lock Control Module Screws ......................................................................................................................... 2-3 Nm (17-26 inch lbs.) 4-Wheel Anti-Lock Control Module Screws .............................................................................................................................. 4-5 Nm (36-44 inch lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Rear Antilock Brake (RABS) Module Electronic Brake Control Module: Locations Rear Antilock Brake (RABS) Module Instrument Panel View The Rear Anti-Lock Brake System Module is located behind right side of the instrument panel. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Rear Antilock Brake (RABS) Module > Page 7202 Electronic Brake Control Module: Locations 4 Wheel Anti-Lock Brake System Module fm99ev326_151-007 The 4 Wheel Anti-Lock Brake System Module is located at the left side of the engine compartment. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > Four Wheel Antilock Brakes Electronic Brake Control Module: Diagrams Four Wheel Antilock Brakes Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Diagrams > Four Wheel Antilock Brakes > Page 7205 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) Electronic Brake Control Module: Service and Repair Four Wheel Anti-Lock Brake System (4WABS) Removal 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Disconnect the battery ground cable. 2. Disconnect the anti-lock brake control module electrical connectors. 3. Disconnect the pump motor electrical connector from the anti-lock brake control module. 4. Remove the anti-lock brake control module. 1 Remove the screws. 2 Remove the anti-lock brake control module. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 7208 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 7209 Electronic Brake Control Module: Service and Repair Rear Antilock Brake System (RABS) Removal 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Disconnect the battery ground cable. 2. Remove the instrument panel cluster panel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 3. Remove the anti-lock brake control module, 1 Disconnect the anti-lock brake control module electrical connector. 2 Remove the bolts. 3 Remove the anti-lock brake control module. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn, the strategy. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Hydraulic Assembly Hydraulic Control Assembly - Antilock Brakes: Specifications Hydraulic Assembly TORQUE SPECIFICATIONS EHCU Bracket Bolts To Frame ................................................................................................................................................. 26-31 Nm (19-23 ft. lbs.) EHCU Bolts To Lower Bracket ................................................................................................................................................. 30-40 Nm (23-29 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Hydraulic Assembly > Page 7214 Hydraulic Control Assembly - Antilock Brakes: Specifications Solenoid Valve Body TORQUE SPECIFICATIONS Rear Anti-Lock Brake Sensor Valve To Rear Axle Brake Junction Block Hydraulic Line ......................................................................................................................... 15-20 Nm (11-14 ft. lbs.) Rear Anti-Lock Brake Sensor Valve Nuts ................................................................................................................................. 21-29 Nm (15-21 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Assembly Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Assembly Removal 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Disconnect the battery ground cable. 2. Disconnect the anti-lock brake control module electrical connectors. 3. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, Rush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: Plug each open port to prevent brake fluid from spilling. Disconnect the hydraulic brake lines. 1 Disconnect the inlet hydraulic brake lines. 2 Disconnect the outlet hydraulic brake lines. 4. Remove the Hydraulic Control Unit (HCU). 1 Remove the bolts. 2 Remove the HCU. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Assembly > Page 7217 5. If necessary, remove the HCU bracket. 1 Remove the bolts. 2 Remove the HCU bracket. Installation 1. If removed, install the HCU bracket. 1 Position the bracket. 2 Install the HCU bracket bolts. 2. Install the HCU. 1 Position the HCU. 2 Install the bolts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Assembly > Page 7218 3. CAUTION: Only authorized Ford inlet hydraulic brake lines should be used. These lines are of specific design and should only be replaced with authorized Ford parts. Connect the hydraulic brake lines. 4. Connect the anti-lock brake control module electrical connectors. 5. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Connect the battery ground cable. 6. Bleed the brake hydraulic system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Assembly > Page 7219 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Solenoid Valve Body Removal 1. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Remove the rear anti-lock brake system (RABS) valve. 1 Disconnect the RABS valve electrical connector. 2 Remove the two hydraulic lines and plug them. 3 Remove the two RABS valve nuts. 4 Remove the RABS valve. Installation 1. To install, reverse the removal procedure. - Bleed the brakes. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Rear Anti-Lock Brakes Wheel Speed Sensor: Specifications Rear Anti-Lock Brake Sensor Rear Anti-Lock Brake Sensor Indicator Clearance 0.005-0.045 in Rear Anti-Lock Brake Sensor Bolt 24-29 ft.lb Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Rear Anti-Lock Brakes > Page 7224 Wheel Speed Sensor: Specifications Front Anti-Lock Brake Sensor Bolt 63-80 in.lb Rear Anti-Lock Brake Sensor Bolt 20 ft.lb Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Rear Wheel Speed Sensor: Service and Repair Rear Removal 1. Raise and support vehicle. 2. NOTE: Clean off dirt and debris that may have collected around the rear anti-lock brake sensor before removal. Remove the rear anti-lock brake sensor. 1 Disconnect the rear anti-lock brake sensor electrical connector. 2 Remove the bolt. 3 Remove the rear anti-lock brake sensor. Installation 1. NOTE: Thoroughly clean the mounting surface. NOTE: Inspect the anti-lock brake sensor 0-ring for damage; lightly lubricate the 0-ring with High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C92-A. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Rear > Page 7227 Wheel Speed Sensor: Service and Repair 4 Wheel Antilock Brake System Front Removal 1. Disconnect the front brake anti-lock sensor electrical connector. 2. Remove the front disc brake rotor shield. 3. Remove the (A) front brake anti-lock sensor bolts and the (B) front brake anti-lock sensor. Installation 1. To install, reverse the removal procedure. Rear Removal 1. Raise and support vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Rear > Page 7228 2. NOTE: Clean off dirt and debris that may have collected around the rear anti-lock brake sensor before removal. Remove the rear anti-lock brake sensor. 1 Disconnect the rear anti-lock brake sensor electrical connector. 2 Remove the bolt. 3 Remove the rear anti-lock brake sensor. Installation 1. NOTE: Thoroughly clean the mounting surface. NOTE: Inspect the anti-lock brake sensor O-ring for damage; lightly lubricate the O-ring with High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure Brake Bleeding: Service and Repair Caliper Bleeding Procedure 1. NOTE: It is not necessary to do a complete brake system bleed if only the disc brake caliper was disconnected. Place a box end wrench on the disc brake caliper bleeder screw. Attach a rubber drain tube to the disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3. Loosen the disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the disc brake caliper bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 4. Tighten the disc brake caliper bleeder screw. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7233 Brake Bleeding: Service and Repair Manual Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or replacement, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 2. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 3. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 4. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 5. Tighten the RH rear bleeder screw. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7234 6. Repeat Steps 2, 3, 4 and 5 for the LH rear bleeder screw. 7. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 8. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 9. Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH front disc brake caliper bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 10. Tighten the RH front disc brake caliper bleeder screw. 11. Repeat Steps 7, 8, 9 and 10 for the LH front disc brake caliper bleeder screw. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7235 Brake Bleeding: Service and Repair Master Cylinder Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or installation of new components, air can enter the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. NOTE: When the brake master cylinder has been replaced or the system has been emptied, or partially emptied, it should be primed to prevent air from entering the system. 1. For in-vehicle priming, disconnect the brake lines. 2. For bench priming, mount the brake master cylinder in a vise. 3. Install short brake tubes with the ends submerged in the brake master cylinder reservoir, and fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 4. Have an assistant pump the brake pedal, or slowly depress the primary piston until clear fluid flows from both brake tubes, without air bubbles. 5. If the brake master cylinder has been primed at the bench, install it in the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7236 6. Remove the short brake tubes, and install the brake outlet tubes. 7. Bleed each brake tube at the brake master cylinder as follows: 1 Have an assistant pump the brake pedal, and then hold firm pressure on the brake pedal. 2 Loosen the rear most brake tube fittings until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the brake tube fitting. 3 Repeat this operation until clear, bubble-free fluid comes out. 4 Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation at the front brake tube. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7237 Brake Bleeding: Service and Repair Pressure Bleeding 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers of pressure bleeding equipment. Follow the instructions of the manufacturer when installing the adapter. Install the bleeder adapter to the brake master cylinder reservoir, and attach the bleeder tank hose to the fitting on the adapter. 3. NOTE: Bleed the longest line first. Make sure the bleeder tank contains enough specified brake fluid to complete the bleeding operation. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 4. Open the valve on the bleeder tank. 5. Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten the RH rear bleeder screw and remove the rubber hose. 6. Continue bleeding the rear of the system, going in order from the LH rear bleeder screw to the RH front disc brake caliper bleeder screw ending with the LH front disc brake caliper bleeder screw. 7. Close the bleeder tank valve. Remove the tank hose from the adapter, and remove the adapter. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7238 Brake Bleeding: Service and Repair 4 Wheel Anti-Lock Brakes (4WABS) NOTE: This procedure only needs to be performed if the 4-Wheel Anti-Lock Brake (4WABS) Hydraulic Control Unit (HCU) has been replaced or if the HCU lines have been opened. 1. Clean all dirt from and remove the brake master cylinder filler cap, and fill the brake master cylinder reservoir with the specified brake fluid. 2. Connect a clear waste line to the RH rear bleeder screw and the other end in a container partially filled with recommended brake fluid. 3. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 4. Tighten the RH rear bleeder screw, and disconnect the waste line. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7239 5. Repeat Steps 2, 3 and 4 for the LH rear bleeder screw, the RH front disc brake caliper bleeder screw, and the LH front disc brake caliper bleeder screw, in that order. 6. Connect the NGS DCL cable adapter into the vehicle Data Link Connector (DLC) under the dash, and follow the NGS instructions. 7. Repeat the system bleed procedure as outlined in Steps 1 through 5. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications Brake Pedal Assy: Specifications TORQUE SPECIFICATIONS Pedal Bracket Bolt And Nuts (Automatic) ........................................................................................................................................... 24 Nm (18 ft. lbs.) Pedal Bracket Bolts (Manual) .................................................................................................. ............................................................. 24 Nm (18 ft. lbs.) Pedal Bracket Nuts (Manual) ................... ............................................................................................................................................. 24 Nm (18 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > With Automatic Transmission Brake Pedal Assy: Service and Repair With Automatic Transmission Removal 1. Disconnect the battery ground cable. 2. Remove the stoplight switch self-locking pin. 3. Slide the stoplight switch and booster push rod off the brake pedal pin. 4. Remove the bulkhead sound insulator. 5. Remove the brake pedal bracket nuts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > With Automatic Transmission > Page 7245 6. CAUTION: Support the brake master cylinder and power brake booster in the engine compartment. Remove the brake pedal bracket bolts and remove brake pedal and bracket. Installation 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > With Automatic Transmission > Page 7246 Brake Pedal Assy: Service and Repair With Manual Transmission Removal 1. Disconnect the clutch master cylinder push rod. 2. Disconnect the Clutch Pedal Position Switch (CPP). 3. Remove the clutch master cylinder by rotating the clutch master cylinder 45 degrees clockwise. 4. Remove the stoplight switch self-locking pin. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > With Automatic Transmission > Page 7247 5. Slide the stoplight switch and the booster push rod off the brake pedal pin. 6. Remove the bulkhead sound insulator. 7. Remove the two brake pedal bracket bolts. 8. Remove the brake pedal bracket nuts. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > With Automatic Transmission > Page 7248 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Description and Operation Brake Warning Indicator: Description and Operation The BRAKE indicator will prove out when the ignition switch is placed in the START and then in the RUN position. The BRAKE indicator will also be illuminated when the instrument cluster receives a ground signal from the parking brake switch or the brake fluid level switch. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Front Disc Brake Caliper Anchor Plate Bolts 136 ft.lb Front Disc Brake Caliper Bolts 21-26 ft.lb Front Brake Caliper Bleeder Screw 13-17 ft.lb Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front Brake Caliper: Service and Repair Front Anchor Plate REMOVAL 1. Remove the pads. NOTE: 4x4 shown, 4x2 similar. 2. Remove the front disc brake caliper anchor plate. 1 Remove the two front disc brake caliper anchor plate bolts. 2 Remove the front disc brake caliper anchor plate. INSTALLATION 1. Install the front disc brake caliper anchor plate. 1 Position the front disc brake caliper anchor plate. 2 Install the front disc brake caliper anchor plate bolts. 2. Install the pads. Disassembly and Assembly Disassembly 1. Remove the disc brake caliper. 2. Drain remaining brake fluid from the disc brake caliper. 3. Secure the disc brake caliper in a vise. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 7258 4. Remove the caliper pistons. 1 Place a block of wood between the caliper bridge and the caliper pistons. 2 Apply low air pressure to the fluid port in the disc brake caliper. 3 Force out the caliper piston to the block of wood. 4 Remove the block of wood and the caliper pistons. 5. Remove and discard the piston seals and boots. 6. NOTE: Do not hone the caliper bores. Pistons are not available for honed caliper bores. If the caliper bores are excessively scored or corroded, install a new disc brake caliper. Assembly 1. CAUTION: Never reuse piston seals or dust boots. NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been allowed to stand in an open container for an extended period of time. Lubricate the piston boot, caliper piston, piston sea], and cylinder bores with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A. 2. Install the caliper pistons. 1 Install the piston seal. 2 Install the piston boot. 3 CAUTION: Be careful not to damage or dislodge the piston seal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 7259 Insert the caliper piston. 4 Press the caliper piston into the caliper bore, being careful not to cock the caliper piston. 3. Install the disc brake caliper. Removal and Installation Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. WARNING: Asbestos fiber dust may be present on brake and clutch assemblies and is hazardous to health if inhaled. Brake and clutch assemblies should be cleaned using a vacuum cleaner recommended for use with asbestos fibers such as a brake/clutch/service vacuum. The bag must be labeled per OSHA instructions, sealed, and the trash hauler notified as to the bag's contents. If a vacuum suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear government-approved toxic dust purifying respirators. Occupational health and safety act (OSHA) requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians performing brake or clutch repair should be present in the area. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Disconnect the front brake hose. 1 Remove the front brake hose bolt. 2 Disconnect the front brake hose. 3 Remove and discard the copper washers. Plug the front brake hose. 4. Remove the disc brake caliper. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 7260 1 Remove the disc brake caliper bolts. 2 Lift the disc brake caliper off the front disc brake caliper anchor plate. 5. Inspect the disc brake caliper for leaks. If leaks are found, disassembly is required. Installation 1. Install the disc brake caliper. 1 Install the disc brake caliper. 2 Install the disc brake caliper bolts. 2. Install the front brake hose. - Use new copper washers; connect the front brake hose. - Install the front brake hose bolt. 3. Bleed the disc brake caliper. 4. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Install the wheel and tire assembly. 5. Inspect the brake system operation. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 7261 Brake Caliper: Service and Repair Rear Adapter ADAPTER Removal 1. Disconnect the rear parking brake cable guide. 2. Remove the axle shaft. 3. Remove the nuts and the rear wheel disc brake adapter. Installation 1. Follow the removal procedure in reverse order. Disassembly and Assembly Special Tools Disassembly 1. Remove the rear disc brake caliper. 2. Drain the remaining brake fluid from the rear disc brake caliper. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 7262 3. Secure the rear disc brake caliper in a vise. 4. Remove the rear disc brake piston. 1 Place a block of wood between the caliper bridge and the rear disc brake piston. 2 Apply low air pressure to the fluid port in the rear disc brake caliper. 3 Force the rear disc brake piston out to the block of wood. 4 Remove the block of wood and the rear disc brake piston. 5. NOTE: Do not hone the cylinder bore. Pistons are not available for honed cylinder bores. If the rear disc brake caliper cylinder bore/piston is excessively scored or corroded, install a new rear disc brake caliper. Remove and discard the piston seal and dust boot. Assembly CAUTION: Never reuse the piston seal or dust boot. NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been allowed to stand in an open container for an extended period of time. 1. Lubricate the following with Ford High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. cylinder bore - piston seal - rear disc brake piston - dust boot Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 7263 2. Install the piston seal. 3. Install the dust boot. 4. CAUTION: Be careful not to damage or dislodge the piston seal. Install the rear disc brake piston. 5. Install the rear disc brake caliper. Removal and Installation Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the wheel and tire assembly. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 7264 3. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Disconnect the brake hose. 1 Remove bolt. 2 Disconnect the rear wheel brake hose. 3 Remove the copper washers and plug the brake hose. 4. CAUTION: Do not remove the guide pins or guide pin boots unless a problem is suspected. The guide pins are meant to be sealed for life and are not repairable. Use Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft WA-10) or an equivalent silicone compound meeting Ford specification ESE-M1C171-A for re-lubing the caliper slide pins. Other greases can swell the guide pin boots, resulting in contamination and accelerated corrosion or wear of the caliper slide pin mechanism. Remove the rear disc brake caliper. 1 Remove the brake caliper bolts. 2 Lift the rear disc brake caliper off the rear disc brake caliper anchor plate. 5. Inspect the rear disc brake caliper for leaks. - If leaks are found, disassembly is required. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 7265 1. CAUTION: To prevent interference with rear disc brake caliper operation, install only the correct caliper bolt. NOTE: Make sure the stainless steel shoe slippers are correctly positioned. Install new if worn or damaged. NOTE: When installed, the locator notch on the brake pads will be located at the upper end of the rear disc brake caliper. Install the rear disc brake caliper. 2. Install the rear wheel brake hose. - Connect the brake hose and install the caliper flow bolt. Use new copper washers. 3. Bleed the disc brake caliper. 4. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Install the wheel and tire assembly. 5. Verify correct brake operation. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Page 7266 Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications Brake Pad: Specifications Front Minimum Pad Thickness Above Metal Backing Plate Or Rivets 0.039 in Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front Brake Pad: Service and Repair Front Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. WARNING: Asbestos fiber dust may be present on brake and clutch assemblies and is hazardous to health if inhaled. Brake and clutch assemblies should be cleaned using a vacuum cleaner recommended for use with asbestos fibers such as a brake/clutch/service vacuum. The bag must be labeled per OSHA instructions, sealed, and the trash hauler notified as to the bag's contents. If a vacuum suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear government-approved toxic dust purifying respirators. Occupational health and safety act (OSHA) requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians performing brake or clutch repair should be present in the area. CAUTION: Replace the pad if worn to or past the specified thickness above the metal backing plate or rivets. Replace the pads in complete axle sets. Inspect the pads for wear or contamination. 4. CAUTION: When removing the front disc brake caliper, never allow it to hang from the brake hose. Provide a suitable support. Remove the disc brake caliper. 1 Remove the two disc brake caliper bolts. 2 Lift the disc brake caliper off the front disc brake caliper anchor plate. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 7272 5. On F-150 4x2 vehicles, measure the brake disc and hub thickness. - Replace the brake disc and hub if not within specification. 6. On all 4x4 vehicles, measure the brake disc thickness. - Replace the brake disc if not within specification. 7. On F-250 4x2 vehicles, measure the brake disc thickness. - Replace the brake disc and hub if not within specification. 8. If necessary, resurface the brake disc. - Ford recommends on-vehicle rotor machining. Follow lathe manufacturer's instructions. 9. Inspect the disc brake caliper for leaks. - If leaks are found, disassembly is required. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 7273 10. Remove the disc brake anti-rattle clips. 1 Remove the pads. 2 Remove the disc brake anti-rattle clips. Installation 1. CAUTION: Do not allow grease, oil, brake fluid or other contaminants to contact the pad lining material. Do not install contaminated pads. Install the pads. 1 Install the disc brake anti-rattle clips. 2 Install the pads. 2. CAUTION: Use care not to damage the bleeder screw or front wheel disc brake shield. Install the disc brake caliper. 1 Install the disc brake caliper. 2 Install the disc brake caliper bolts. 3. Install the tire and wheel assembly. 4. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Inspect brake operation. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 7274 Brake Pad: Service and Repair Rear Removal 1. Inspect the brake pads for wear or contamination. Install new if worn to or past specification. 2. NOTE: It is not necessary to remove the rear wheel brake hose when performing this procedure. Remove the rear disc brake caliper. 3. CAUTION: Do not allow grease, oil, brake fluid or other contaminants to contact the brake pads. Remove the brake pads. 4. Retract the caliper piston into the rear disc brake caliper. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Front > Page 7275 5. Remove the slippers. Installation 1. Clean the slipper mating surface, and install the slippers. 2. CAUTION: Install new brake pads in full axle sets. Do not install new brake pads on only one side of vehicle. Install the brake pads. 3. Install the rear disc brake caliper. 4. Verify correct brake operation. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brake Rotor - Incorrect Discard Thickness Specification Brake Rotor/Disc: Technical Service Bulletins Brake Rotor - Incorrect Discard Thickness Specification Article No. 99-25-6 12/13/99 ^ BRAKES - INCORRECT ROTOR THICKNESS STAMPED ON ROTOR - F-150 4X2 ONLY ^ BRAKES - INCORRECT WORKSHOP MANUAL ROTOR DISCARD THICKNESS SPECIFICATION FORD: 1997-2000 EXPEDITION, F-150, F-250 LD LINCOLN: 1998-2000 NAVIGATOR ISSUE The 1997-2000 Workshop Manuals do not provide the correct and complete specification for rotor discard thickness. Additionally, some 4X2 F-150 rotors may have an incorrect rotor discard thickness stamped on them. Updated Information Per TSB 99-25-6 ACTION Refer to the Front and Rear Disc Rotor Discard Specification Charts for correct rotor discard specification. * SOME 4X2 F-150 ROTORS SHOW "24.7 mm" PRINTED ON THE ROTOR BACK SIDE. THIS IS AN ERROR, THESE CAN BE CUT TO 24.5 mm DISCARD THICKNESS. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 390000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Brake Rotor/Disc Brake Rotor/Disc: Specifications Brake Rotor/Disc Front Brakes Front Brake Disc 4x2 NASCAR & Heavy Duty Minimum Thickness ............................................................................................................................. ...................................... 1.091" in. ( 27.70 mm. ) 4x2 With 4 wheel ABS and Lighting Minimum Thickness ............................................................................................................................. ........................................ 0.98" in. ( 24.70 mm. ) 4x4 With 5M12 Wheel Bolts Minimum Thickness ............................................................................................................................. ...................................... 0.965" in. ( 24.50 mm. ) Rear Brakes Rear Brake Disc Minimum Thickness ............................................................................................................................. ....................................... 0.48" in. ( 12.00 mm. ) Runout .................................................................... ......................................................................................................................................... 0.0003" in. Thickness Variation ............................................................................................................................. ............................................................ 0.0004" in. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Brake Rotor/Disc > Page 7282 Brake Rotor/Disc: Specifications Disc Backing Plate TORQUE SPECIFICATIONS Brake Disc Shield Bolts ....................................................................................................................... ........................................ 10-14 Nm (7-10 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor/Disc Brake Rotor/Disc: Service and Repair Brake Rotor/Disc Front Removal 1. Remove the front disc brake caliper anchor plate. 2. On 4x4 vehicles, remove the brake disc. 3. On 4x2 vehicles, remove the brake disc and hub as follows: 1 Remove the hub grease cap. 2 Remove the cotter pin. 3 Remove the nut retainer. 4 Remove the spindle nut. 5 Remove the front wheel outer bearing retainer washer. 6 Remove the outer front wheel bearing. 7 Remove the brake disc and hub. 4. If necessary on 4x2 vehicles, remove the front wheel bearing. 1 Remove the wheel hub grease seal. 2 Remove the front wheel bearing. Installation 1. On 4x4 vehicles, position the brake disc to the wheel hub. - Use Metal Brake Parts Cleaner F3AZ-19579-SA or equivalent to clean the brake disc and hub. 2. On 4x2 vehicles, thoroughly clean and inspect the front wheel bearings and the brake disc and hub. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor/Disc > Page 7285 - Use Metal Brake Parts Cleaner F3AZ-19579-SA or equivalent. 3. On 4x2 vehicles, lubricate the front wheel bearings. Use Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B. 4. On 4x2 vehicles, install a new wheel hub grease seal. 1 Install the inner front wheel bearing. 2 Install a new wheel hub grease seal. 5. On 42 vehicles, install the brake disc and hub. 1 Position the brake disc and hub. 2 Install the outer front wheel bearing. 3 Install the front wheel outer bearing retainer washer. 4 Install the spindle nut. 6. While rotating the brake disc and hub, tighten the spindle nut. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor/Disc > Page 7286 7. Loosen the spindle nut two turns. 8. Tighten the spindle nut while rotating the brake disc and hub. 9. Loosen the spindle nut. 10. Tighten the spindle nut while rotating the brake disc and hub. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor/Disc > Page 7287 11. On 4x2 vehicles, install the following components: 1 Install the nut retainer. 2 Install the cotter pin. 3 Install the hub grease cap. 12. Install the front disc brake caliper anchor plate. Rear Removal 1. NOTE: When removing the rear brake disc in this procedure it is necessary to disconnect the hydraulic lines. Remove the rear disc brake caliper. 2. NOTE: If the rear brake disc binds on the rear parking brake shoe and linings, remove the adjustment hole access plug and contract the parking brake shoe and lining. Remove the rear brake disc. 3. CAUTION: Use a hub-mount brake lathe if necessary to machine the rear brake disc. Measure the rear brake disc, and resurface as necessary. Install a new rear brake disc if beyond specification. Installation 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor/Disc > Page 7288 Brake Rotor/Disc: Service and Repair Disc Backing Plate Front Removal 1. Remove the brake disc. 2. On 4x4 vehicles, remove the wheel hub. 3. On 4x2 vehicles, remove the brake disc shield. 1 Remove the three bolts. 2 Remove the brake disc shield. 4. On 4x4 vehicles, remove the brake disc shield. 1 Remove the bolts. 2 Remove the brake disc shield. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor/Disc > Page 7289 1. Follow the removal procedure in reverse order. Rear Removal 1. Remove the rear wheel disc brake adapter. 2. Remove the rear wheel disc brake shield. 1 Drill out the rivet. 2 Remove the rear wheel disc brake shield. Installation 1. NOTE: Because the rear wheel disc brake shield is held in position by the four rear wheel disc brake adapter bolts, a new rivet is not required. Seal the rivet hole with Silicone Rubber D6AZ- 19562-AA or equivalent meeting Ford specification ESB-M4G92-A, and install the rear wheel disc brake shield. 2. Install the rear wheel disc brake adapter. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications Backing Plate: Specifications TORQUE SPECIFICATIONS Brake Backing Plate Nuts .................................................................................................................................................... 54.5-68.1 Nm (40-50 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications > Page 7294 Backing Plate: Service and Repair Removal 1. Remove the rear brake shoes and linings. 2. Remove the axle shaft or the axle shaft and rear hub. 3. Compress the cable retainer and pull the parking brake rear cable and conduit from the brake backing plate. 4. Remove the rear wheel cylinder. 1 Disconnect the brake line fitting. 2 Remove the two rear wheel cylinder bolts. 3 Remove the rear wheel cylinder. 5. Remove the four backing plate-to-axle flange nuts and bolts and the brake backing plate. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information > Specifications > Page 7295 1. Follow the removal procedure in reverse order. 2. Bleed the brake system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications Brake Drum: Specifications Rear Drum Brake Maximum Diameter ............................................................................................................................. ................................... 11.090" in. ( 281.69 mm. ) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 7299 Brake Drum: Service and Repair Special Tools Removal WARNING: Asbestos fiber dust may be present on brake and clutch assemblies and is hazardous to health if inhaled. WARNING: Brake and clutch assemblies should be cleaned using a vacuum cleaner recommended for use with asbestos fibers such as brake/clutch/service vacuum. The bag must be labeled per OSHA instructions, sealed, and the trash hauler notified as to the bag's contents. WARNING: If a vacuum suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear government-approved toxic dust purifying respirators. WARNING: Occupational health and safety act (OSHA) requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians performing brake or clutch repair should be present in the area. 1. NOTE: Make sure the parking brake control is fully released. Relieve tension on parking brake system. 1 Pull the front parking brake cable and conduit. 2 Insert a suitable retainer pin. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 7300 2. WARNING: If so equipped, the electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support vehicle. 3. Remove the wheel and tire assembly. 4. CAUTION: Use of a brake drum puller or a torch is not recommended. Brake drum distortion may result. NOTE: If the brake drum is rusted to the axle shaft flange, tap the center of the brake drum. Remove the brake drum. 1 Remove and discard the spring nut. 2 Remove the rear brake drum. 5. NOTE: If the brake drum will not come off, follow these steps. Loosen the brake adjuster screw. 1 Disengage the brake shoe adjusting lever from the brake adjuster screw. 2 Use a brake adjustment tool to loosen the brake adjuster screw. 6. On Standard, use a brake drum micrometer to measure the brake drum inside diameter. Replace if brake drum exceeds maximum inside diameter. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 7301 7. On Heavy-Duty, use a brake drum micrometer to measure the brake drum inside diameter. Replace if brake drum exceeds maximum inside diameter. Installation WARNING: Improperly tightened lug nuts could allow the wheel to come off while the vehicle is in motion, causing loss of control. 1. If adjusting the rear brakes with brake drums removed. 2. Install the brake drum. 3. If adjusting the rear brakes with the brake drums installed. 4. WARNING: Always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub or brake drum that contacts the wheel. Installing wheels without proper metal to metal contact at the wheel mounting surfaces can cause the lug nuts to loosen and could allow the wheel to come off while the vehicle is in motion, causing loss of control. Clean the wheel hub mounting surface. 5. Install the tire and wheel assembly. 6. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. 7. Remove the pin in the parking brake control and verify proper parking brake operation. 8. Check brake operation before driving. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 7302 Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Customer Interest for Brake Shoe: > 01-19-2 > Oct > 01 > Rear Brakes - Grabbing On First Few Applications Brake Shoe: Customer Interest Rear Brakes - Grabbing On First Few Applications Article No. 01-19-2 10/01/01 BRAKES - REAR DRUM - GRABBING DURING FIRST FEW BRAKE APPLICATIONS WHILE BRAKES ARE COLD FORD: 1997-2000 F-150 This article is being republished in its entirety to update the Model Year coverage. ISSUE A grabbing condition from the rear brakes during the first few brake applications after extended humidity exposure may occur on some vehicles. This may be caused by a rear brake lining that is sensitive to humidity exposure. ACTION Replace rear brake linings with revised Rear Shoe Brake Kit (F85Z-2200-AA). Refer to the appropriate model year F-150 Workshop Manual, Section 206-02 for service details. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-10-7 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011902A Replace Rear Brake Shoes 1.2 Hrs. DEALER CODING CONDITION BASIC PART NO. CODE 2200 49 OASIS CODES: 301000, 702200 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Shoe: > 01-19-2 > Oct > 01 > Rear Brakes - Grabbing On First Few Applications Brake Shoe: All Technical Service Bulletins Rear Brakes - Grabbing On First Few Applications Article No. 01-19-2 10/01/01 BRAKES - REAR DRUM - GRABBING DURING FIRST FEW BRAKE APPLICATIONS WHILE BRAKES ARE COLD FORD: 1997-2000 F-150 This article is being republished in its entirety to update the Model Year coverage. ISSUE A grabbing condition from the rear brakes during the first few brake applications after extended humidity exposure may occur on some vehicles. This may be caused by a rear brake lining that is sensitive to humidity exposure. ACTION Replace rear brake linings with revised Rear Shoe Brake Kit (F85Z-2200-AA). Refer to the appropriate model year F-150 Workshop Manual, Section 206-02 for service details. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-10-7 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011902A Replace Rear Brake Shoes 1.2 Hrs. DEALER CODING CONDITION BASIC PART NO. CODE 2200 49 OASIS CODES: 301000, 702200 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Page 7316 Brake Shoe: Specifications Lining Minimum Thickness Standard 1/32 in Heavy Duty 1/32 in Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Adjustments > Drums Installed Brake Shoe: Adjustments Drums Installed 1. Raise and support the vehicle. 2. At the back of the brake backing plate, remove the brake adjusting hole cover. 3. Rotate the brake shoe adjusting screw nut. 1 Using a screwdriver, move the brake shoe adjusting lever off the brake shoe adjusting screw nut. 2 NOTE: Move the adjustment tool handle upward to tighten the brake adjuster screw. Turn the brake shoe adjusting screw nut until the brake drum begins to drag. Then loosen the brake adjuster screw until the brake drum rotates freely. 4. Replace the brake adjusting hole cover. 5. Lower the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Adjustments > Drums Installed > Page 7319 Brake Shoe: Adjustments Drums Removed WARNING: Asbestos fiber dust can be present on brake and clutch assemblies and is hazardous to health if inhaled. Brake and clutch assemblies must be cleaned using a vacuum cleaner recommended for use with asbestos fibers, such as a brake/clutch/service vacuum. The bag must be labeled per OSHA instructions, sealed, and the trash hauler notified as to the bag's contents. If a vacuum suitable for asbestos is not available, cleaning must be done wet. If dust generation is still possible, technicians must wear government-approved toxic dust purifying respirators. The occupational safety and health act (OSHA) requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians performing brake or clutch repair are to be present in the area. NOTE: After adjusting the rear brake shoes and linings, check the parking brake for proper operation. Make sure the parking brake cable equalizer operates freely. 1. Measure the brake drum inside diameter. - Use a brake adjustment gauge. 2. Adjust the rear brake shoes and linings. - Rotate the brake adjuster screw until the rear brake shoes and linings touch the tool. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Heavy-Duty Brake Shoe: Service and Repair Heavy-Duty Special Tools Removal WARNING: Asbestos fiber dust can be present on brake and clutch assemblies and is hazardous to health if inhaled. Brake and clutch assemblies must be cleaned using a vacuum cleaner recommended for use with asbestos fibers, such as the brake/clutch/service vacuum. The bag must be labeled per OSHA instructions, sealed, and the trash hauler notified as to the bag's contents. If a vacuum suitable for asbestos is not available, cleaning must be done wet. If dust generation is still possible, technicians must wear government-approved toxic dust purifying respirators. The occupational safety and health act (OSHA) requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians performing brake or clutch repair are to be present in the area. WARNING: To reduce the possibility of uneven braking, always replace rear brake shoes and linings at both ends of an axle. 1. Remove the brake drum. 2. Inspect the rear brake assembly for the following: - the rear wheel cylinder for excessive leakage that can contaminate brake system parts, and rebuild as necessary. - the rear brake shoes and linings for contamination, and replace as necessary. - the rear brake shoes and linings for minimum thickness above backing plate or rivets, and replace as necessary. - the springs for heat discoloration, and replace as necessary. 3. Remove the brake shoe retracting spring. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Heavy-Duty > Page 7322 4. Disconnect the parking brake lever. 1 Remove the parking brake lever bolt lock nut, at the back of the brake backing plate, and the parking brake lever bolt. 2 Remove the parking brake rear cable and conduit from the parking brake lever. 5. Remove the parking brake lever. 6. Remove the adjusting screw assembly. 1 Disconnect the brake shoe adjusting lever cable from the brake shoe adjusting lever. 2 Remove the brake shoe adjusting lever cable. 3 Remove the cable guide, 4 Remove the adjusting lever return spring and the brake shoe adjusting lever. 5 Remove the brake shoe adjusting screw spring. 6 Remove the brake adjuster screw assembly. 7. Remove the rear brake shoe and lining. 1 Remove the brake shoe anchor pin guide plate. 2 Remove the brake shoe hold-down springs and the brake shoe hold-down spring pins. 3 Remove the rear brake shoes and linings. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Heavy-Duty > Page 7323 1. Lubricate the brake backing plate friction points. Use Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft WA-10) or an equivalent silicone compound meeting Ford specification ESE-M1C171-A. 2. Install the rear brake shoes and linings. 1 Position the rear brake shoes and linings. 2 Install the brake shoe hold-down spring pins and the brake shoe hold-down springs. 3 Install the brake shoe anchor pin guide plate. 3. NOTE: To prevent incorrect installation, the socket end of each brake adjuster screw is stamped R or L. Assemble the brake adjuster screw assembly. 1 Apply Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft WA-10) or an equivalent silicone compound meeting Ford specification ESE-M1C171-A. 2 Install the brake adjuster screw into the brake shoe adjusting screw nut to the end of the threads, and then loosen one-half turn. 3 Install the brake shoe adjusting screw socket on the brake shoe adjusting screw nut. 4. Install the brake adjuster screw assembly. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Heavy-Duty > Page 7324 1 Position the brake adjuster screw assembly. 2 Install the brake shoe adjusting screw spring. 3 Position the brake shoe adjusting lever cable. 4 Install the cable guide. 5 Position the adjusting lever return spring and the brake shoe adjusting lever. 6 Hook the brake shoe adjusting lever cable to the brake shoe adjusting lever. 5. Test the operation of the automatic self-adjuster. 1 Pull the brake shoe adjusting lever cable and check that the brake shoe adjusting lever rotates the brake shoe adjuster assembly. 2 Release the brake shoe adjusting lever cable and check that the brake shoe adjusting lever advances to the next notch on the brake shoe adjusting screw nut. 6. Install the parking brake lever. 1 Attach the parking brake rear cable and conduit to the parking brake lever. 2 Position the parking brake lever. 3 Install the parking brake lever bolt and, at the back of the brake backing plate, the parking brake lever bolt lock nut. 7. Install the brake shoe retracting spring. 8. Adjust the brakes. 9. Install the brake drum. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Heavy-Duty > Page 7325 Brake Shoe: Service and Repair Standard Special Tools Removal 1. Remove the brake drum. 2. Inspect the rear brake assembly for the following: - the rear wheel cylinder for excessive leakage that can contaminate brake system parts, and rebuild as necessary. - the rear brake shoes and linings for contamination, and replace as necessary. - the rear brake shoes and linings for minimum thickness, above the backing plate or rivets, and replace as necessary. - the springs for heat discoloration, and replace as necessary. - the adjusting lever contact with the brake adjuster screw. 3. NOTE: To aid installation, note the locations of the short and long brake shoe retracting springs. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Heavy-Duty > Page 7326 Remove the brake shoe retracting springs. 1 Remove the long brake shoe retracting spring. 2 Remove the short brake shoe retracting spring. 4. Remove the adjusting screw assembly. 1 Disconnect the brake shoe adjusting lever cable from the brake shoe adjusting lever. 2 Remove the brake shoe adjusting lever cable. 3 Remove the cable guide. 4 Remove the adjusting lever return spring and the brake shoe adjusting lever. 5 Remove the brake shoe adjusting screw spring. 6 Remove the brake adjuster screw assembly. 5. NOTE: The parking brake link spring and the brake parking spring retainer will come off with the parking brake strut. Remove the brake shoe anchor pin guide plate, parking brake strut and the parking brake lever pin retainer. 6. Remove the rear brake shoes and linings. 1 Remove the brake shoe hold-down springs. 2 Remove the rear brake shoes and linings. 3 Remove the brake shoe hold-down spring pins. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Heavy-Duty > Page 7327 7. Pull back the parking brake cable spring and disconnect the parking brake lever. Installation 1. Compress the parking brake cable spring and attach the parking brake lever. 2. Clean and lubricate the brake backing plate. - Use Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft WA-10) or an equivalent silicone compound meeting Ford specification ESE-M1C171-A. 3. Attach the parking brake lever to the rear brake shoe and lining and secure the parking brake lever pin retainer. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Heavy-Duty > Page 7328 4. Install the rear brake shoes and linings. 1 Position the rear brake shoes and linings. 2 Install the brake shoe hold-down spring pins and the brake shoe hold-down springs. 5. Install the parking brake strut. 1 Install the parking brake link spring and the parking brake spring retainer on the parking brake strut. 2 Install the parking brake strut. 3 Install the brake shoe anchor pin guide plate. 6. Install the short brake shoe retracting spring. 1 Place the brake shoe adjusting lever cable over the anchor pin, with crimped side in. 2 Install the short brake shoe retracting spring. 7. NOTE: Make sure the brake shoe adjusting lever cable is positioned in the cable guide groove. Install the long brake shoe retracting spring. 1 Install the cable guide. 2 Position the brake shoe adjusting lever cable in the cable guide groove. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Heavy-Duty > Page 7329 3 Install the long brake shoe retracting spring. 8. NOTE: To prevent incorrect installation, the socket end of each brake adjuster screw is stamped R or L. Assemble the brake adjuster screw assembly. 1 Apply Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft WA-10) or an equivalent silicone compound meeting Ford specification ESE-M1C171-A. 2 Install the brake adjuster screw into the brake shoe adjusting screw nut to the end of the threads, and then loosen one-half turn. 3 Install the brake shoe adjusting screw socket on the brake shoe adjusting screw nut. 9. Install the brake adjuster screw assembly. 1 Position the brake adjuster screw assembly. 2 Install the brake shoe adjusting screw spring. 3 Position the brake shoe adjusting lever cable. 4 Position the adjusting lever return spring and the brake shoe adjusting lever. 5 Hook the brake shoe adjusting lever cable to the brake shoe adjusting lever. 10. Test the operation of the automatic self-adjuster. 1 Pull the brake shoe adjusting lever cable and check that the brake shoe adjusting lever rotates the brake shoe adjuster assembly. 2 Release the brake shoe adjusting lever cable and check that the brake shoe adjusting lever advances to the next notch on the brake shoe adjusting screw nut. 11. Adjust the brakes. 12. Install the brake drum. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Page 7330 Brake Shoe: Tools and Equipment Special Tool Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications Wheel Cylinder Bleeder Screw 62-79 in.lb Rear Wheel Cylinder Bolts 9-13 ft.lb Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Removal and Installation Wheel Cylinder: Service and Repair Removal and Installation Removal 1. Remove the brake shoes and linings. 2. Remove the rear wheel cylinder. 1 Disconnect the brake line fitting. 2 Remove the two rear wheel cylinder bolts. 3 Remove the rear wheel cylinder. Installation 1. Follow the removal procedure in reverse order. 2. Bleed the brake system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Service and Repair > Removal and Installation > Page 7336 Wheel Cylinder: Service and Repair Disassembly And Assembly Disassembly 1. NOTE: Removal is not necessary to disassemble, inspect, hone or overhaul the rear wheel cylinder. Disassemble the rear wheel cylinder. 1 Remove the rubber boots. 2 Remove the rear wheel cylinder pistons. 3 Remove the cups. 4 Remove the expander. 5 Remove the wheel cylinder bleeder screw from the rear wheel cylinder. Assembly 1. NOTE: Coat all the rear wheel cylinder parts with Ford High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. Follow the disassembly procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure Brake Bleeding: Service and Repair Caliper Bleeding Procedure 1. NOTE: It is not necessary to do a complete brake system bleed if only the disc brake caliper was disconnected. Place a box end wrench on the disc brake caliper bleeder screw. Attach a rubber drain tube to the disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3. Loosen the disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the disc brake caliper bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 4. Tighten the disc brake caliper bleeder screw. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7342 Brake Bleeding: Service and Repair Manual Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or replacement, air may get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 2. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid. 3. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 4. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 5. Tighten the RH rear bleeder screw. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7343 6. Repeat Steps 2, 3, 4 and 5 for the LH rear bleeder screw. 7. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber drain tube to the RH front disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 8. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 9. Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH front disc brake caliper bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 10. Tighten the RH front disc brake caliper bleeder screw. 11. Repeat Steps 7, 8, 9 and 10 for the LH front disc brake caliper bleeder screw. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7344 Brake Bleeding: Service and Repair Master Cylinder Bleeding WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: When any part of the hydraulic system has been disconnected for repair or installation of new components, air can enter the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been properly connected. The hydraulic system can be bled manually or with pressure bleeding equipment. NOTE: When the brake master cylinder has been replaced or the system has been emptied, or partially emptied, it should be primed to prevent air from entering the system. 1. For in-vehicle priming, disconnect the brake lines. 2. For bench priming, mount the brake master cylinder in a vise. 3. Install short brake tubes with the ends submerged in the brake master cylinder reservoir, and fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. 4. Have an assistant pump the brake pedal, or slowly depress the primary piston until clear fluid flows from both brake tubes, without air bubbles. 5. If the brake master cylinder has been primed at the bench, install it in the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7345 6. Remove the short brake tubes, and install the brake outlet tubes. 7. Bleed each brake tube at the brake master cylinder as follows: 1 Have an assistant pump the brake pedal, and then hold firm pressure on the brake pedal. 2 Loosen the rear most brake tube fittings until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the brake tube fitting. 3 Repeat this operation until clear, bubble-free fluid comes out. 4 Refill the brake master cylinder reservoir as necessary. Repeat the bleeding operation at the front brake tube. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7346 Brake Bleeding: Service and Repair Pressure Bleeding 1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master cylinder reservoir with the specified brake fluid. 2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers of pressure bleeding equipment. Follow the instructions of the manufacturer when installing the adapter. Install the bleeder adapter to the brake master cylinder reservoir, and attach the bleeder tank hose to the fitting on the adapter. 3. NOTE: Bleed the longest line first. Make sure the bleeder tank contains enough specified brake fluid to complete the bleeding operation. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake fluid. 4. Open the valve on the bleeder tank. 5. Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten the RH rear bleeder screw and remove the rubber hose. 6. Continue bleeding the rear of the system, going in order from the LH rear bleeder screw to the RH front disc brake caliper bleeder screw ending with the LH front disc brake caliper bleeder screw. 7. Close the bleeder tank valve. Remove the tank hose from the adapter, and remove the adapter. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7347 Brake Bleeding: Service and Repair 4 Wheel Anti-Lock Brakes (4WABS) NOTE: This procedure only needs to be performed if the 4-Wheel Anti-Lock Brake (4WABS) Hydraulic Control Unit (HCU) has been replaced or if the HCU lines have been opened. 1. Clean all dirt from and remove the brake master cylinder filler cap, and fill the brake master cylinder reservoir with the specified brake fluid. 2. Connect a clear waste line to the RH rear bleeder screw and the other end in a container partially filled with recommended brake fluid. 3. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw. Repeat until clear, bubble-free fluid comes out. - Refill the brake master cylinder reservoir as necessary. 4. Tighten the RH rear bleeder screw, and disconnect the waste line. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Caliper Bleeding Procedure > Page 7348 5. Repeat Steps 2, 3 and 4 for the LH rear bleeder screw, the RH front disc brake caliper bleeder screw, and the LH front disc brake caliper bleeder screw, in that order. 6. Connect the NGS DCL cable adapter into the vehicle Data Link Connector (DLC) under the dash, and follow the NGS instructions. 7. Repeat the system bleed procedure as outlined in Steps 1 through 5. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications Brake Caliper: Specifications Front Disc Brake Caliper Anchor Plate Bolts 136 ft.lb Front Disc Brake Caliper Bolts 21-26 ft.lb Front Brake Caliper Bleeder Screw 13-17 ft.lb Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front Brake Caliper: Service and Repair Front Anchor Plate REMOVAL 1. Remove the pads. NOTE: 4x4 shown, 4x2 similar. 2. Remove the front disc brake caliper anchor plate. 1 Remove the two front disc brake caliper anchor plate bolts. 2 Remove the front disc brake caliper anchor plate. INSTALLATION 1. Install the front disc brake caliper anchor plate. 1 Position the front disc brake caliper anchor plate. 2 Install the front disc brake caliper anchor plate bolts. 2. Install the pads. Disassembly and Assembly Disassembly 1. Remove the disc brake caliper. 2. Drain remaining brake fluid from the disc brake caliper. 3. Secure the disc brake caliper in a vise. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 7354 4. Remove the caliper pistons. 1 Place a block of wood between the caliper bridge and the caliper pistons. 2 Apply low air pressure to the fluid port in the disc brake caliper. 3 Force out the caliper piston to the block of wood. 4 Remove the block of wood and the caliper pistons. 5. Remove and discard the piston seals and boots. 6. NOTE: Do not hone the caliper bores. Pistons are not available for honed caliper bores. If the caliper bores are excessively scored or corroded, install a new disc brake caliper. Assembly 1. CAUTION: Never reuse piston seals or dust boots. NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been allowed to stand in an open container for an extended period of time. Lubricate the piston boot, caliper piston, piston sea], and cylinder bores with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A. 2. Install the caliper pistons. 1 Install the piston seal. 2 Install the piston boot. 3 CAUTION: Be careful not to damage or dislodge the piston seal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 7355 Insert the caliper piston. 4 Press the caliper piston into the caliper bore, being careful not to cock the caliper piston. 3. Install the disc brake caliper. Removal and Installation Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the wheel and tire assembly. 3. WARNING: Asbestos fiber dust may be present on brake and clutch assemblies and is hazardous to health if inhaled. Brake and clutch assemblies should be cleaned using a vacuum cleaner recommended for use with asbestos fibers such as a brake/clutch/service vacuum. The bag must be labeled per OSHA instructions, sealed, and the trash hauler notified as to the bag's contents. If a vacuum suitable for asbestos is not available, cleaning should be done wet. If dust generation is still possible, technicians should wear government-approved toxic dust purifying respirators. Occupational health and safety act (OSHA) requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians performing brake or clutch repair should be present in the area. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Disconnect the front brake hose. 1 Remove the front brake hose bolt. 2 Disconnect the front brake hose. 3 Remove and discard the copper washers. Plug the front brake hose. 4. Remove the disc brake caliper. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 7356 1 Remove the disc brake caliper bolts. 2 Lift the disc brake caliper off the front disc brake caliper anchor plate. 5. Inspect the disc brake caliper for leaks. If leaks are found, disassembly is required. Installation 1. Install the disc brake caliper. 1 Install the disc brake caliper. 2 Install the disc brake caliper bolts. 2. Install the front brake hose. - Use new copper washers; connect the front brake hose. - Install the front brake hose bolt. 3. Bleed the disc brake caliper. 4. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Install the wheel and tire assembly. 5. Inspect the brake system operation. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 7357 Brake Caliper: Service and Repair Rear Adapter ADAPTER Removal 1. Disconnect the rear parking brake cable guide. 2. Remove the axle shaft. 3. Remove the nuts and the rear wheel disc brake adapter. Installation 1. Follow the removal procedure in reverse order. Disassembly and Assembly Special Tools Disassembly 1. Remove the rear disc brake caliper. 2. Drain the remaining brake fluid from the rear disc brake caliper. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 7358 3. Secure the rear disc brake caliper in a vise. 4. Remove the rear disc brake piston. 1 Place a block of wood between the caliper bridge and the rear disc brake piston. 2 Apply low air pressure to the fluid port in the rear disc brake caliper. 3 Force the rear disc brake piston out to the block of wood. 4 Remove the block of wood and the rear disc brake piston. 5. NOTE: Do not hone the cylinder bore. Pistons are not available for honed cylinder bores. If the rear disc brake caliper cylinder bore/piston is excessively scored or corroded, install a new rear disc brake caliper. Remove and discard the piston seal and dust boot. Assembly CAUTION: Never reuse the piston seal or dust boot. NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been allowed to stand in an open container for an extended period of time. 1. Lubricate the following with Ford High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. cylinder bore - piston seal - rear disc brake piston - dust boot Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 7359 2. Install the piston seal. 3. Install the dust boot. 4. CAUTION: Be careful not to damage or dislodge the piston seal. Install the rear disc brake piston. 5. Install the rear disc brake caliper. Removal and Installation Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the wheel and tire assembly. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 7360 3. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Disconnect the brake hose. 1 Remove bolt. 2 Disconnect the rear wheel brake hose. 3 Remove the copper washers and plug the brake hose. 4. CAUTION: Do not remove the guide pins or guide pin boots unless a problem is suspected. The guide pins are meant to be sealed for life and are not repairable. Use Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft WA-10) or an equivalent silicone compound meeting Ford specification ESE-M1C171-A for re-lubing the caliper slide pins. Other greases can swell the guide pin boots, resulting in contamination and accelerated corrosion or wear of the caliper slide pin mechanism. Remove the rear disc brake caliper. 1 Remove the brake caliper bolts. 2 Lift the rear disc brake caliper off the rear disc brake caliper anchor plate. 5. Inspect the rear disc brake caliper for leaks. - If leaks are found, disassembly is required. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 7361 1. CAUTION: To prevent interference with rear disc brake caliper operation, install only the correct caliper bolt. NOTE: Make sure the stainless steel shoe slippers are correctly positioned. Install new if worn or damaged. NOTE: When installed, the locator notch on the brake pads will be located at the upper end of the rear disc brake caliper. Install the rear disc brake caliper. 2. Install the rear wheel brake hose. - Connect the brake hose and install the caliper flow bolt. Use new copper washers. 3. Bleed the disc brake caliper. 4. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Install the wheel and tire assembly. 5. Verify correct brake operation. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Page 7362 Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications Brake Fluid: Specifications Hydraulic brake fluid color must conform with the requirements of Federal Motor Vehicle Safety Standard 116. Under this standard, brake fluids are visually different from other automotive fluids such as transmission, power steering and engine oil. High Performance DOT3 Brake Fluid Ford Specification ESA-M6C25-A Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Service Precautions > Technician Safety Information Brake Fluid: Technician Safety Information SAFETY PRECAUTIONS WARNING: Brake fluid may be irritating to the skin or eyes. In case of contact, take the following actions: ^ Eye Contact - rinse eyes thoroughly with water. ^ Skin Contact - wash skin with soap and water. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Service Precautions > Technician Safety Information > Page 7368 Brake Fluid: Vehicle Damage Warnings WARNING: Brake fluid contains polyglycol. ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Clean, fresh Ford High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A is the only brake fluid that should be used in Ford vehicles. Do not reuse brake fluid drained or bled from the system. - Do not use brake fluid that has been stored in an open container. - Do not use contaminated brake fluid. - Do not mix different types of brake fluid. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 7372 Brake Fluid Level Sensor/Switch: Description and Operation The brake master cylinder fluid level warning switch is an integral part of the brake master cylinder reservoir. It consists of a float containing a magnet and a reed switch mounted in the bottom of the brake master cylinder reservoir. When the brake fluid in the brake master cylinder reservoir gets to a predetermined level, the floating magnet actuates the reed switch, causing the red brake warning indicator to illuminate. Loss of brake fluid from either the primary (front) hydraulic circuit or secondary (rear) hydraulic circuit will cause the warning indicator to activate. If the brake fluid level warning switch is inoperative, the brake master cylinder reservoir must be installed new. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Brake Hose Brake Hose/Line: Specifications Brake Hose TORQUE SPECIFICATIONS Front Brake Hose Bracket .......................................................................................................................................................... 13-17 Nm (10-12 ft. lbs.) Front Brake Hose Plug ................................................................................ ............................................................................... 13-17 Nm (10-12 ft. lbs.) Front Brake Hose Bolt . .............................................................................................................................................................. 13-17 Nm (10-12 ft. lbs.) Rear Brake Hose Frame Bolt (LH/RH) ........................................................................................................................................ 12-15 Nm (9-11 ft. lbs.) Rear Brake Hose Bolt ..................................................................................................... ........................................................... 30-40 Nm (23-29 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Brake Hose > Page 7377 Brake Hose/Line: Specifications Brake Line TORQUE SPECIFICATIONS Brake Line-to-Rear Wheel Cylinder Fitting ............................................................................................................................... 15-20 Nm (11-14 ft. lbs.) Front Brake Tube ..................................................................................................................... .................................................. 15-20 Nm (12-14 ft. lbs.) Front Master Cylinder Brake Tube ............................................................................................................................................ 22-28 Nm (17-20 ft. lbs.) Rear Brake Tube .......................................................................................................... .............................................................. 15-20 Nm (12-14 ft. lbs.) Rear Master Cylinder Brake Tube ............................................................................................................................................. 15-20 Nm (12-14 ft. lbs.) 1/2-20 Hydraulic Brake Line ..................................................................................................................................................... 21-29 Nm (15-20 ft. lbs.) 7/16-24 Hydraulic Brake Line ................................................................................................................................................... 15-20 Nm (12-14 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > Page 7378 Brake Hose/Line: Description and Operation When replacing hydraulic brake tubing, hoses, or connectors, tighten all connections securely. After replacement, bleed the brake system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation Brake Proportioning/Combination Valve: Description and Operation The brake master cylinder fluid control valve regulates the hydraulic pressure in the rear hydraulic circuit. It is located on the brake master cylinder and is screwed into the rear most outlet port. When the brake pedal is applied, the full brake pressure passes through the brake master cylinder fluid control valve to the rear hydraulic circuit until the valve's split point is reached. Above its split point, the brake master cylinder fluid control valve begins to reduce the hydraulic pressure to the rear brakes, creating a balanced braking condition between the front and rear wheels to minimize rear wheel lockup during hard braking. In case of front brake system malfunction, the brake master cylinder fluid control valve has a bypass feature which allows full hydraulic pressure to the rear brake system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Hydraulic Assembly Hydraulic Control Assembly - Antilock Brakes: Specifications Hydraulic Assembly TORQUE SPECIFICATIONS EHCU Bracket Bolts To Frame ................................................................................................................................................. 26-31 Nm (19-23 ft. lbs.) EHCU Bolts To Lower Bracket ................................................................................................................................................. 30-40 Nm (23-29 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Hydraulic Assembly > Page 7386 Hydraulic Control Assembly - Antilock Brakes: Specifications Solenoid Valve Body TORQUE SPECIFICATIONS Rear Anti-Lock Brake Sensor Valve To Rear Axle Brake Junction Block Hydraulic Line ......................................................................................................................... 15-20 Nm (11-14 ft. lbs.) Rear Anti-Lock Brake Sensor Valve Nuts ................................................................................................................................. 21-29 Nm (15-21 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Assembly Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Assembly Removal 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Disconnect the battery ground cable. 2. Disconnect the anti-lock brake control module electrical connectors. 3. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, Rush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. NOTE: Plug each open port to prevent brake fluid from spilling. Disconnect the hydraulic brake lines. 1 Disconnect the inlet hydraulic brake lines. 2 Disconnect the outlet hydraulic brake lines. 4. Remove the Hydraulic Control Unit (HCU). 1 Remove the bolts. 2 Remove the HCU. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Assembly > Page 7389 5. If necessary, remove the HCU bracket. 1 Remove the bolts. 2 Remove the HCU bracket. Installation 1. If removed, install the HCU bracket. 1 Position the bracket. 2 Install the HCU bracket bolts. 2. Install the HCU. 1 Position the HCU. 2 Install the bolts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Assembly > Page 7390 3. CAUTION: Only authorized Ford inlet hydraulic brake lines should be used. These lines are of specific design and should only be replaced with authorized Ford parts. Connect the hydraulic brake lines. 4. Connect the anti-lock brake control module electrical connectors. 5. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Connect the battery ground cable. 6. Bleed the brake hydraulic system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Assembly > Page 7391 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Solenoid Valve Body Removal 1. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Remove the rear anti-lock brake system (RABS) valve. 1 Disconnect the RABS valve electrical connector. 2 Remove the two hydraulic lines and plug them. 3 Remove the two RABS valve nuts. 4 Remove the RABS valve. Installation 1. To install, reverse the removal procedure. - Bleed the brakes. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Master Cylinder, ABS Brake Master Cylinder: Specifications Master Cylinder, ABS TORQUE SPECIFICATIONS Brake Master Cylinder To Rear Anti-Lock Brake Sensor Valve Hydraulic Line ..................................................................................................................................... 15-20 Nm (11-14 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Master Cylinder, ABS > Page 7396 Brake Master Cylinder: Specifications Master Cylinder, Brakes TORQUE SPECIFICATIONS Brake Master Cylinder Fluid Control Valve .............................................................................................................................. 30-49 Nm (22-36 ft. lbs.) Brake Master Cylinder Nut ........................................................................................................................................................ 22-28 Nm (17-20 ft. lbs.) Brake Pressure Switch ................................................................................ ................................................................................ 15-20 Nm (12-14 ft. lbs.) Front Master Cylinder Brake Tube ........................................................................................................................................... 22-28 Nm (17-20 ft. lbs.) Rear Master Cylinder Brake Tube ............................................................................................................................................ 15-20 Nm (12-14 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 7397 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 7398 Brake Master Cylinder: Description and Operation The brake master cylinder is a dual-piston type, The brake master cylinder is assisted by a power brake booster. The following conditions are considered normal and not indications that the brake master cylinder is in need of repair or replacement: Low brake fluid level detected without signs of leakage. This condition is caused by displacement of brake fluid to the disc brake calipers to compensate for normal brake wear. Add brake fluid as needed. - A momentary or slight squirt of brake fluid from the brake master cylinder reservoir upon application of the brake pedal. - A trace of brake fluid found on the outside of the power brake booster below the brake master cylinder mounting flange. This condition results from the lubricating action of the brake master cylinder wiping seal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 7399 Brake Master Cylinder: Testing and Inspection Normal Conditions The following conditions are considered normal and are not indications that the brake master cylinder is in need of repair. Condition 1: During normal operation of the brake master cylinder, the fluid level in the brake master cylinder reservoir will rise during brake application and fall during release. The net fluid level (after brake application and release) will remain unchanged. Condition 2: A trace of brake fluid will exist on the booster shell below the master cylinder mounting flange. This results from the normal lubricating action of the master cylinder bore and seal. Condition 3: Fluid level will decrease with pad wear. Abnormal Conditions Changes in brake pedal feel or travel are indicators that something could be wrong in the brake system. Refer to the Symptom Chart for abnormal condition diagnosis. See: Testing and Inspection/Symptom Related Diagnostic Procedures Bypass Condition Test To perform this test: 1. Disconnect the brake lines at the brake master cylinder. 2. Plug the outlet ports of the brake master cylinder. 3. Apply the brakes. If brake pedal height cannot be maintained, the brake master cylinder has an internal leak and must be rebuilt or a new master cylinder installed. Compensator Port Check The purpose of the compensator ports in the brake master cylinder is to supply any additional brake fluid required by the system due to brake pad wear and to allow brake fluid returning from the brake lines to the brake master cylinder to enter the brake master cylinder reservoir. The returning brake fluid will cause a slight turbulence in the brake master cylinder reservoir. Turbulence seen in the brake master cylinder reservoir upon release of the brake pedal is normal and shows that the compensating ports are not plugged. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 7400 Brake Master Cylinder: Adjustments 1. Remove the brake master cylinder. 2. CAUTION: Do not apply the brake pedal with the master cylinder removed from the booster. Adjust the power brake booster to brake master cylinder push rod, vacuum applied. 1 Measure the power brake booster to brake master cylinder push rod. 2 If necessary, adjust the screw to the proper length. 3. Install the brake master cylinder. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir Brake Master Cylinder: Service and Repair Brake Fluid Reservoir Removal WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. 1. Disconnect the brake master cylinder fluid level warning switch. 2. Use a suitable suction device to drain the brake master cylinder reservoir. 3. Carefully pry up on the brake master cylinder reservoir to remove. Installation 1. NOTE: Whenever installing anew brake master cylinder reservoir, install new grommets. Install the brake master cylinder reservoir. 1 Lubricate the two grommets with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A, and insert the grommets in the brake master cylinder. 2 Press the brake master cylinder reservoir into the grommets until it snaps. 3 Connect the brake master cylinder fluid level warning switch. 4 Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 7403 Brake Master Cylinder: Service and Repair Master Cylinder, Brakes Disassembly and Assembly Disassembly WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. 1. Remove the brake master cylinder. 2. Clean the outside of the brake master cylinder. 3. Remove the brake master cylinder filler cap and drain the remaining brake fluid. 4. If equipped, remove the brake pressure switch. 5. Remove the brake master cylinder fluid control valve. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 7404 6. Remove the primary piston assembly. 1 Depress the primary piston and remove the snap ring. 2 Remove and discard the primary piston assembly. 7. Remove the secondary piston assembly. 1 Plug the rear outlet port and, if necessary, plug the brake pressure switch port. 2 Apply compressed air into the front outlet port and remove the secondary piston assembly and discard. 8. NOTE: If the brake master cylinder bore is damaged, the brake master cylinder must be installed new. Use isopropyl alcohol to clean and inspect the brake master cylinder bore for damage. Assembly WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. 1. Use clean High-Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A, to lubricate the new piston assembly seals. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 7405 2. Carefully install the secondary piston assembly. 3. Carefully install the primary piston assembly. 4. Install the snap ring. 1 Depress the primary piston. 2 Install the snap ring. 5. Install the brake master cylinder fluid control valve. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 7406 6. If equipped, install the brake pressure switch. 7. Install the brake master cylinder. 8. Fill the brake master cylinder reservoir with High-Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A and install the brake master cylinder filler cap. 9. Bleed the brake master cylinder. Removal and Installation Removal WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. 1. Disconnect the brake fluid level warning switch. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 7407 2. If equipped with speed control, disconnect the brake pressure switch electrical connector. 3. Disconnect the two brake lines and plug the lines and the brake master cylinder ports. 4. On vehicles equipped with the Rear Anti-Lock Brake System (RABS), remove the RABS valve. 5. Remove the brake master cylinder. 1 Remove the two brake master cylinder nuts. 2 Remove the brake master cylinder. Installation 1. Follow the removal procedure in reverse order. - Bleed the brake system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications Wheel Cylinder Bleeder Screw 62-79 in.lb Rear Wheel Cylinder Bolts 9-13 ft.lb Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Removal and Installation Wheel Cylinder: Service and Repair Removal and Installation Removal 1. Remove the brake shoes and linings. 2. Remove the rear wheel cylinder. 1 Disconnect the brake line fitting. 2 Remove the two rear wheel cylinder bolts. 3 Remove the rear wheel cylinder. Installation 1. Follow the removal procedure in reverse order. 2. Bleed the brake system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Service and Repair > Removal and Installation > Page 7413 Wheel Cylinder: Service and Repair Disassembly And Assembly Disassembly 1. NOTE: Removal is not necessary to disassemble, inspect, hone or overhaul the rear wheel cylinder. Disassemble the rear wheel cylinder. 1 Remove the rubber boots. 2 Remove the rear wheel cylinder pistons. 3 Remove the cups. 4 Remove the expander. 5 Remove the wheel cylinder bleeder screw from the rear wheel cylinder. Assembly 1. NOTE: Coat all the rear wheel cylinder parts with Ford High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. Follow the disassembly procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Specifications Parking Brake Cable: Specifications TORQUE SPECIFICATIONS Parking Brake Cable And Conduit Clip Bolt ............................................................................................................................. 17-23 Nm (13-17 ft. lbs.) Cable Support Bracket Bolt ......................................................................................................... ......................................................... 44 Nm (32 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Rear Disc Parking Brake Cable: Service and Repair Rear Disc Removal 1. NOTE: Make sure the parking brake control is fully released. Relieve the tension on the parking brake system. 1 Pull the front parking brake cable and conduit. 2 Insert a suitable retainer. 2. Disconnect the front parking brake cable and conduit from the RH parking brake rear cable and conduit. - Pull the front parking brake cable and conduit rearward to unclip it from the RH parking brake rear cable and conduit. 3. Remove the front door scuff plate. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Rear Disc > Page 7420 4. Remove the cowl side trim panel. 5. Disconnect the front parking brake cable and conduit. 1 Compress the connector to release the front parking brake cable and conduit. 2 Disconnect the front parking brake cable and conduit. 3 Remove the front parking brake cable and conduit. 6. Remove the front parking brake cable and conduit. 1 Pry the rubber seal from the front floor pan. 2 Unclip the front parking brake cable and conduit from the front parking brake cable clip. 3 Compress the retainer and release the front parking brake cable and conduit from the bracket. 4 Remove the front parking brake cable and conduit. Installation 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Rear Disc > Page 7421 Parking Brake Cable: Service and Repair Rear Removal 1. NOTE: Make sure the parking brake control is fully released. Relieve the tension on the parking brake system. 1 Pull the front parking brake cable and conduit. 2 Insert a suitable retainer. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 3. Disconnect the front parking brake cable and conduit from the RH parking brake rear cable and conduit. Pull the RH parking brake rear cable and conduit forward to unclip it from the front parking brake cable and conduit. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Rear Disc > Page 7422 4. On F-150, remove the parking brake cable equalizer spring. 5. For the RH parking brake rear cable and conduit compress the retainer and remove it from the parking brake cable equalizer. 6. For the LH parking brake rear cable and conduit, remove it from the parking brake cable equalizer. 1 Unhook the cable end from the equalizer bracket. 2 Compress the retainer and remove the parking brake rear cable and conduit. 7. NOTE: This step is only necessary when removing the RH parking brake rear cable and conduit. Disconnect the parking brake rear cable and conduit from the axle housing. 1 Unclip the rear parking brake rear cable and conduit from the clip. 2 Remove the cable support bracket bolt. 8. For vehicles with drum brakes remove the brake drum. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Rear Disc > Page 7423 9. On F-150, disconnect the parking brake cable from the parking brake lever. 10. On F-150, remove the parking brake rear cable and conduit. 1 Compress the retainers. 2 Remove the parking brake rear cable and conduit. 11. On F-250, remove the parking brake rear cable and conduit. 1 Compress the retainers. 2 Remove the parking brake rear cable and conduit. Installation 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications Parking Brake Control: Specifications TORQUE SPECIFICATIONS Parking Brake Control Nuts/bolts .............................................................................................................................................. 15-20 Nm (11-14 ft. lbs.) Parking Brake Control To Bracket Nuts .................................................................................................................................... 15-20 Nm (11-14 ft. lbs.) Parking Brake Control Release Handle To Instrument Panel ........................................................................................................................................... 2.1-2.9 Nm (19-26 inch lbs.) Parking Brake Control Bracket To Cowl Panel Bolts ............................................................................................................................................................ 15-20 Nm (11-14 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 7427 Parking Brake Control: Service and Repair Removal 1. NOTE: Make sure the parking brake control is fully released. Relieve the tension on the parking brake system. 1 Pull the front parking brake cable and conduit. 2 Insert a suitable retainer. 2. Remove the front door scuff plate. 3. Remove the cowl side trim panel. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 7428 4. Pull to release the three clips and remove the lower instrument panel steering column cover. 5. Disconnect the parking brake control release handle. 1 Remove the screws. 2 Disconnect the release handle from the release cable. 6. Separate the parking brake control from the mounting bracket. 1 Disconnect the parking brake signal switch electrical connector. 2 Remove the parking brake control nuts. 3 Separate the parking brake control from the mounting bracket. 7. Disconnect the cables. - Disconnect the front parking brake cable and conduit from the parking brake control. - Disconnect the release cable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Specifications > Page 7429 8. Remove the parking brake control. 1 Compress the connector to release the front parking brake cable and conduit. 2 Remove the front parking brake cable and conduit. 3 Remove the parking brake control. Installation 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Switch > Component Information > Specifications Parking Brake Release Switch: Specifications TORQUE SPECIFICATIONS Parking Brake Release Handle Screws ................................................................................................................................. 2.7-3.7 Nm (25-33 inch lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Technical Service Bulletins > Brakes - Reduced Power Assist in Freezing Temperatures Vacuum Brake Booster: Technical Service Bulletins Brakes - Reduced Power Assist in Freezing Temperatures Article No. 01-25-5 12/24/01 BRAKES - REDUCED POWER ASSIST DURING OPERATION IN FREEZING AMBIENT TEMPERATURES - LIGHTNING MODELS ONLY FORD: 1999-2001 F-150 ISSUE Some Lightning model vehicles may exhibit a reduced power assist after the first two or three brake applications during operation in freezing ambient temperatures. This may be caused by current production routing of the brake booster vacuum hose allowing water to collect in the hose which can freeze in cold ambient temperatures. ACTION Verify condition only occurs during freezing ambient temperatures. Replace existing brake booster hose with a new design service part. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove existing brake booster hose and discard. 2. Install new brake booster hose (1L3Z-9C482-AA). Secure new. hose by inserting retainer (included) into the upper hole on the driver's side of the cowl trim panel (Figure 1). 3.. Road test and verify brake effectiveness. Parts Block Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Technical Service Bulletins > Brakes - Reduced Power Assist in Freezing Temperatures > Page 7438 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 012505A Replace Brake Booster 0.8 Hr. Vacuum Supply Line DEALER CODING CONDITION BASIC PART NO. CODE 9C482 55 OASIS CODES: 301000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Technical Service Bulletins > Page 7439 Vacuum Brake Booster: Specifications OPERATIONAL SPECIFICATIONS Brake Booster Push Rod Length ............................................................................................................................... 24.89-25.27 mm (0.980-0.995 inch) TORQUE SPECIFICATIONS Power Brake Booster Nuts .................................................................................................................. ................................................. 24 Nm (18 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Technical Service Bulletins > Page 7440 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Technical Service Bulletins > Page 7441 Vacuum Brake Booster: Description and Operation The power brake booster: is a dual diaphragm, vacuum assisted power brake booster. - reduces brake pedal pressure and travel distance. - is located on the LH side of the bulkhead in the engine compartment, between the brake pedal and brake master cylinder. - is divided into separate chambers by the diaphragm. - will not operate if vacuum is restricted or if any of the vacuum related power brake components fail. - is replaced as an assembly. If the power assist fails, the brake system will continue to operate with increased brake pedal effort. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Technical Service Bulletins > Page 7442 Vacuum Brake Booster: Service and Repair Removal 1. Remove the brake master cylinder. 2. Disconnect the power brake booster hose. 1 Compress the clamp. 2 Disconnect the power brake booster hose. 3. Remove the stoplight switch self-locking pin. 4. Slide the stoplight switch and booster push rod off the brake pedal pin. 5. Remove the bulkhead sound insulator. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Technical Service Bulletins > Page 7443 6. Remove the power brake booster nuts and remove booster. Installation 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Description and Operation Vacuum Brake Booster Check Valve: Description and Operation The power brake booster check valve: is located on the front of the power brake booster. - is positioned between the power brake booster and the power brake booster hose. - closes when the engine is turned off. - in the closed position, traps engine vacuum in the power brake booster. - retains vacuum to provide several power assisted brake applications with the engine off. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Specifications Electronic Brake Control Module: Specifications TORQUE SPECIFICATIONS Rear Wheel Anti-Lock Control Module Screws ......................................................................................................................... 2-3 Nm (17-26 inch lbs.) 4-Wheel Anti-Lock Control Module Screws .............................................................................................................................. 4-5 Nm (36-44 inch lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Rear Antilock Brake (RABS) Module Electronic Brake Control Module: Locations Rear Antilock Brake (RABS) Module Instrument Panel View The Rear Anti-Lock Brake System Module is located behind right side of the instrument panel. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Rear Antilock Brake (RABS) Module > Page 7453 Electronic Brake Control Module: Locations 4 Wheel Anti-Lock Brake System Module fm99ev326_151-007 The 4 Wheel Anti-Lock Brake System Module is located at the left side of the engine compartment. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Four Wheel Antilock Brakes Electronic Brake Control Module: Diagrams Four Wheel Antilock Brakes Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Diagrams > Four Wheel Antilock Brakes > Page 7456 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) Electronic Brake Control Module: Service and Repair Four Wheel Anti-Lock Brake System (4WABS) Removal 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Disconnect the battery ground cable. 2. Disconnect the anti-lock brake control module electrical connectors. 3. Disconnect the pump motor electrical connector from the anti-lock brake control module. 4. Remove the anti-lock brake control module. 1 Remove the screws. 2 Remove the anti-lock brake control module. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 7459 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Service and Repair > Four Wheel Anti-Lock Brake System (4WABS) > Page 7460 Electronic Brake Control Module: Service and Repair Rear Antilock Brake System (RABS) Removal 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result. Disconnect the battery ground cable. 2. Remove the instrument panel cluster panel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 3. Remove the anti-lock brake control module, 1 Disconnect the anti-lock brake control module electrical connector. 2 Remove the bolts. 3 Remove the anti-lock brake control module. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn, the strategy. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations > Page 7465 Brake Fluid Level Sensor/Switch: Description and Operation The brake master cylinder fluid level warning switch is an integral part of the brake master cylinder reservoir. It consists of a float containing a magnet and a reed switch mounted in the bottom of the brake master cylinder reservoir. When the brake fluid in the brake master cylinder reservoir gets to a predetermined level, the floating magnet actuates the reed switch, causing the red brake warning indicator to illuminate. Loss of brake fluid from either the primary (front) hydraulic circuit or secondary (rear) hydraulic circuit will cause the warning indicator to activate. If the brake fluid level warning switch is inoperative, the brake master cylinder reservoir must be installed new. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Release Switch > Component Information > Specifications Parking Brake Release Switch: Specifications TORQUE SPECIFICATIONS Parking Brake Release Handle Screws ................................................................................................................................. 2.7-3.7 Nm (25-33 inch lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Rear Anti-Lock Brakes Wheel Speed Sensor: Specifications Rear Anti-Lock Brake Sensor Rear Anti-Lock Brake Sensor Indicator Clearance 0.005-0.045 in Rear Anti-Lock Brake Sensor Bolt 24-29 ft.lb Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Rear Anti-Lock Brakes > Page 7473 Wheel Speed Sensor: Specifications Front Anti-Lock Brake Sensor Bolt 63-80 in.lb Rear Anti-Lock Brake Sensor Bolt 20 ft.lb Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Rear Wheel Speed Sensor: Service and Repair Rear Removal 1. Raise and support vehicle. 2. NOTE: Clean off dirt and debris that may have collected around the rear anti-lock brake sensor before removal. Remove the rear anti-lock brake sensor. 1 Disconnect the rear anti-lock brake sensor electrical connector. 2 Remove the bolt. 3 Remove the rear anti-lock brake sensor. Installation 1. NOTE: Thoroughly clean the mounting surface. NOTE: Inspect the anti-lock brake sensor 0-ring for damage; lightly lubricate the 0-ring with High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C92-A. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Rear > Page 7476 Wheel Speed Sensor: Service and Repair 4 Wheel Antilock Brake System Front Removal 1. Disconnect the front brake anti-lock sensor electrical connector. 2. Remove the front disc brake rotor shield. 3. Remove the (A) front brake anti-lock sensor bolts and the (B) front brake anti-lock sensor. Installation 1. To install, reverse the removal procedure. Rear Removal 1. Raise and support vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Rear > Page 7477 2. NOTE: Clean off dirt and debris that may have collected around the rear anti-lock brake sensor before removal. Remove the rear anti-lock brake sensor. 1 Disconnect the rear anti-lock brake sensor electrical connector. 2 Remove the bolt. 3 Remove the rear anti-lock brake sensor. Installation 1. NOTE: Thoroughly clean the mounting surface. NOTE: Inspect the anti-lock brake sensor O-ring for damage; lightly lubricate the O-ring with High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 7483 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 7484 Clutch Switch: Description and Operation The Clutch Pedal Position (CPP) switch is controlled by the clutch pedal. Depressing the clutch pedal manually closes the CPP switch and allows engine cranking. The CPP switch will also deactivate the speed control system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch > Component Information > Locations > Page 7485 Clutch Switch: Service and Repair REMOVAL 1. Disconnect the Clutch Pedal Position switch (CPP) electrical connector. 2. Release the clutch pedal position switch from the orientation clip. 3. Remove the plastic retainer. 1 Push the lock tabs together. 2 Slide the plastic retainer off the clutch pedal position switch. 4. Remove the clutch pedal position switch. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 7491 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 7492 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 7493 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 7494 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 7495 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 7496 Ignition Switch Lock Cylinder: Specifications TORQUE SPECIFICATIONS Lock Cylinder Housing Screws .................................................................................................................................................. 18-26 Nm (14-19 ft. lbs.) Key Release Button Bolt ............................................................................................................................................................ 4-6 Nm (36-53 inch lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Lock Cylinder Ignition Switch Lock Cylinder: Service and Repair Functional Lock Cylinder Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1. Insert the ignition key and turn to the RUN position. 2. Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock cylinder. Installation 1. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Lock Cylinder > Page 7499 Ignition Switch Lock Cylinder: Service and Repair Key Release Button Removal 1. Remove the ignition switch lock cylinder. 1. Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2. Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. 2. Twist the tilt wheel handle and shank and remove. 3. Release the four clips and remove the steering column opening cover. 4. Remove the upper and lower steering column shrouds. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Lock Cylinder > Page 7500 1. Remove the three screws. 2. Remove the lower steering column shroud. 3. Remove the upper steering column shroud. 5. Remove the key release button. 1. Remove the bolt. 2. Remove the spring. 3. Remove the key release button. Installation 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Lock Cylinder > Page 7501 Ignition Switch Lock Cylinder: Service and Repair Non-Functional Lock Cylinder Removal WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Lock Cylinder > Page 7502 4. Remove the ignition switch lock cylinder. ^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. ^ Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. ^ Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. 6. Remove the bearing and the gear. ^ Thoroughly clean all drill shavings from the steering column and inspect it for damage. Installation The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Lock Cylinder > Page 7503 1. NOTE: Use a new ignition switch lock cylinder. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Specifications Starter Relay: Specifications Starter Motor Solenoid Relay Switch Bolts ........................................................................................................................................ 7-9 N.m (61-79 Lb-In) Starter Motor Solenoid Relay Switch Terminal Nuts .......................................................................................................................... 5-7 N.m (44-62 Lb-In) Starter Motor Solenoid Relay Switch Cable Nuts .......................................................................................................................... 5-11.2 N.m (45-99 Lb-In) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Description and Operation > Automatic Transmission Starter Relay: Description and Operation Automatic Transmission The starter motor solenoid relay switch: - controls current to the starter solenoid. - is engaged by the ignition switch. - connects the battery to the starter motor. The digital TR sensor prevents starter motor engagement unless the transmission is in the NEUTRAL or PARK position. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Description and Operation > Automatic Transmission > Page 7513 Starter Relay: Description and Operation Manual Transmission The starter motor solenoid relay switch: - controls current to the starter solenoid. - is engaged by the ignition switch. - connects the battery to the starter motor. The Clutch Pedal Position (CPP) switch prevents starter motor engagement unless the clutch pedal is pressed. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Description and Operation > Page 7514 Starter Relay: Testing and Inspection Use the 73 Digital Multimeter to check for continuity between terminal 85 and all other terminals. If resistance is 5 ohms or less between terminal 85 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay terminals 86 and 30 directly to the positive battery terminal. Use the 73 Digital Multimeter set in the volts position to check for voltage at terminal 87A. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect a third jumper wire to terminal 85 and ground the jumper wire to a know good ground. Check for voltage at terminal 87. If battery voltage is not indicated, replace the relay. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Description and Operation > Page 7515 Starter Relay: Service and Repair REMOVAL WARNING: WHEN CARRYING OUT MAINTENANCE ON THE STARTING SYSTEM BE AWARE THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE PROTECTIVE CAPS ARE IN PLACE WHEN MAINTENANCE IS COMPLETE. FAILURE TO FOLLOW THIS PROCEDURE MAY RESULT IN PERSONAL INJURY. 1. Disconnect the battery ground cable. 2. Remove the insulator. 3. Disconnect the starter motor solenoid relay switch wires and cables. - Disconnect the engine control sensor wiring terminal. - Remove the starter motor solenoid relay switch terminal nuts. - Remove the wiring. 4. Remove the starter motor solenoid relay switch. - Remove the bolts. - Remove the starter motor solenoid relay switch. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Description and Operation > Page 7516 WARNING: WHEN CARRYING OUT MAINTENANCE ON THE STARTING SYSTEM BE AWARE THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE PROTECTIVE CAPS ARE IN PLACE WHEN MAINTENANCE IS COMPLETE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair Battery Cable: Service and Repair REMOVAL 1. Disconnect the battery ground cables. 1 Disconnect the battery ground cable. 2 Disconnect the battery to starter relay cable. 2. Remove the nuts. 3. Remove the (A) negative battery cable body ground nut, and the (B) starter motor ground. 4. Remove the bolt. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Page 7521 5. Remove the starter motor solenoid terminal cover. 6. Disconnect the starter motor connections. 1 Remove the (A) starter motor ground cable nut and disconnect the (B) starter motor ground cable. 2 Remove the (C) solenoid cable nut and disconnect the (D) solenoid cable. 3 Remove the (E) starter motor positive cable nut and disconnect the (F) starter motor positive cable. 7. Remove the cables. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Service and Repair > Page 7522 1. Follow the removal procedure in reverse order. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 kilometers (10 miles) or more to relearn the strategy. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Alternator Brush > Component Information > Specifications Alternator Brush: Specifications Brush and Terminal Holder Screws .................................................................................................................................................... 3-4 N.m (27-35 Lb-In) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Alternator Pulley > Component Information > Specifications Alternator Pulley: Specifications Generator Pulley Nut ........................................................................................................................... .......................................... 82-135 N.m (61-99 Lb-Ft) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Specifications Voltage Regulator: Specifications Voltage Regulator Screws ............................................................................................................................................................ 2.3-3.4 N.m (20-30 Lb-In) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Specifications > Page 7534 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Specifications > Page 7535 Voltage Regulator: Application and ID Voltage Regulator ................................................................................................................................ ....................................................................... Integral Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Specifications > Page 7536 Voltage Regulator: Service and Repair REMOVAL NOTE: The voltage regulator is serviceable as an assembly only. 1. Remove the Generator. 2. Remove the (A) generator brush and terminal holder and the (B) voltage regulator assembly. 1 Remove the screws. 2 Remove the (A) generator brush and terminal holder and (B) voltage regulator assembly. INSTALLATION 1. Install the (A) generator brush and terminal holder and the (B) voltage regulator assembly. 1 Depress the (C) brushes and insert a (D) wire to hold brushes during installation. 2 Install the (A) generator brush and terminal holder and the (B) voltage regulator assembly. 3 Install the screws and remove the (D) wire. 2. Install Generator. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Locations > Page 7541 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Locations > Page 7542 Clutch Switch: Description and Operation The Clutch Pedal Position (CPP) switch is controlled by the clutch pedal. Depressing the clutch pedal manually closes the CPP switch and allows engine cranking. The CPP switch will also deactivate the speed control system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Locations > Page 7543 Clutch Switch: Service and Repair REMOVAL 1. Disconnect the Clutch Pedal Position switch (CPP) electrical connector. 2. Release the clutch pedal position switch from the orientation clip. 3. Remove the plastic retainer. 1 Push the lock tabs together. 2 Slide the plastic retainer off the clutch pedal position switch. 4. Remove the clutch pedal position switch. INSTALLATION 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > Customer Interest: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder Ignition Lock: Customer Interest Ignition Key - Hard To Remove From Ignition Cylinder Article No. 99-16-4 08/09/99 ^ IGNITION KEY - HARD TO REMOVE FROM IGNITION CYLINDER ^ IGNITION KEY - HARD TO TURN FORD: 1992-1999 ECONOLINE 1997-1999 EXPEDITION, F-150, F-25C 1999 SUPER DUTY F SERIES LINCOLN: 1998-1999 NAVIGATOR This TSB article is being republished in its entirety to add vehicles covered by this TSB. ISSUE A hard to turn ignition key, and/or a hard to remove key from ignition cylinder may occur on some vehicles. This may be caused by a misaligned shift column shaft bushing. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > Customer Interest: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder > Page 7552 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > Customer Interest: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder > Page 7553 ACTION A diagnostic and repair procedure has been developed to correctly repair the concern. Refer to the following Figures 1 through 3 for details. PART NUMBER PART NAME F3TZ-7L278-A Shift Column Shaft Bushing OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-5-9 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991604A Replace Ignition Lock 0.4 Hr. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > Customer Interest: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder > Page 7554 Cylinder 991604B Replace Bushings 1.1 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 7335 42 OASIS CODES: 112000, 602300 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder Ignition Lock: All Technical Service Bulletins Ignition Key - Hard To Remove From Ignition Cylinder Article No. 99-16-4 08/09/99 ^ IGNITION KEY - HARD TO REMOVE FROM IGNITION CYLINDER ^ IGNITION KEY - HARD TO TURN FORD: 1992-1999 ECONOLINE 1997-1999 EXPEDITION, F-150, F-25C 1999 SUPER DUTY F SERIES LINCOLN: 1998-1999 NAVIGATOR This TSB article is being republished in its entirety to add vehicles covered by this TSB. ISSUE A hard to turn ignition key, and/or a hard to remove key from ignition cylinder may occur on some vehicles. This may be caused by a misaligned shift column shaft bushing. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder > Page 7560 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder > Page 7561 ACTION A diagnostic and repair procedure has been developed to correctly repair the concern. Refer to the following Figures 1 through 3 for details. PART NUMBER PART NAME F3TZ-7L278-A Shift Column Shaft Bushing OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-5-9 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 991604A Replace Ignition Lock 0.4 Hr. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 99-16-4 > Aug > 99 > Ignition Key - Hard To Remove From Ignition Cylinder > Page 7562 Cylinder 991604B Replace Bushings 1.1 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 7335 42 OASIS CODES: 112000, 602300 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Lock: > 00-8-4 > Apr > 00 > Differential - Chattering On Turns Differential Clutch: All Technical Service Bulletins Differential - Chattering On Turns Article No. 00-8-4 DATE: 04/17/2000 ^ NOISE - "CHATTERING" FROM REAR AXLE HEARD ON TURNS OR WHEN CORNERING VEHICLES WITH LIMITED SLIP AXLE ^ AXLE - LIMITED SLIP - REAR AXLE "CHATTERING" NOISE ON TURNS OR WHEN CORNERING FORD: 1999-2000 E-150, EXPEDITION, F-150 LINCOLN: 1999-2000 NAVIGATOR ISSUE A "chattering" noise from the rear axle may be heard when turning or cornering. This may be due to differentials containing clutch packs that have been gauged too tightly. ACTION Install new Traction-Lok Clutch Pack Kit. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Confirm axle chatter with road test. 2. Once axle chatter has been confirmed, remove and discard old clutch packs, shims and Belleville springs. Refer to the appropriate Workshop Manual for details. NOTE: Subtract O.25 mm (0.010") from feeler gauge reading taken during shim selection using service tools and procedures indicated on instruction sheets packaged with kits. 3. Install Clutch Pack Kit F75Z-4947-AA for 9.75" ring gear Traction-Lok axles or Clutch Pack Kit F75Z-4947-AB for 10.25 " ring gear Traction-Lok axles. For ring gear size and differential type, see embossed metal tag attached to rear axle cover. Refer to the appropriate Workshop Manual for details. PART NUMBER PART NAME F752-4947-AA Clutch Pack Kit (9.75" Ring Gear) F75Z-4947-AB Clutch Pack Kit (10.25" Ring Gear) OTHER APPLICABLE ARTICLES: NONE Operation Information Operarion numbers description and times Dealer Coding Dealer part number and condition code Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Lock: > 00-8-4 > Apr > 00 > Differential - Chattering On Turns > Page 7568 Oasis Coding Oasis codes WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Lock: > 00-8-4 > Apr > 00 > Differential - Chattering On Turns > Page 7574 Oasis Coding Oasis codes WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Ignition Switch Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 7580 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 7581 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 7582 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 7583 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 7584 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 7585 Ignition Switch Lock Cylinder: Specifications TORQUE SPECIFICATIONS Lock Cylinder Housing Screws .................................................................................................................................................. 18-26 Nm (14-19 ft. lbs.) Key Release Button Bolt ............................................................................................................................................................ 4-6 Nm (36-53 inch lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Lock Cylinder Ignition Switch Lock Cylinder: Service and Repair Functional Lock Cylinder Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1. Insert the ignition key and turn to the RUN position. 2. Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock cylinder. Installation 1. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Lock Cylinder > Page 7588 Ignition Switch Lock Cylinder: Service and Repair Key Release Button Removal 1. Remove the ignition switch lock cylinder. 1. Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2. Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder. 2. Twist the tilt wheel handle and shank and remove. 3. Release the four clips and remove the steering column opening cover. 4. Remove the upper and lower steering column shrouds. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Lock Cylinder > Page 7589 1. Remove the three screws. 2. Remove the lower steering column shroud. 3. Remove the upper steering column shroud. 5. Remove the key release button. 1. Remove the bolt. 2. Remove the spring. 3. Remove the key release button. Installation 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Lock Cylinder > Page 7590 Ignition Switch Lock Cylinder: Service and Repair Non-Functional Lock Cylinder Removal WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel. 3. Twist off the cap from the ignition switch lock cylinder. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Lock Cylinder > Page 7591 4. Remove the ignition switch lock cylinder. ^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin. ^ Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition switch lock cylinder breaks loose. ^ Remove and discard the ignition switch lock cylinder and drill shavings from the steering column. 5. Remove the bearing retainer. 6. Remove the bearing and the gear. ^ Thoroughly clean all drill shavings from the steering column and inspect it for damage. Installation The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Functional Lock Cylinder > Page 7592 1. NOTE: Use a new ignition switch lock cylinder. Follow the removal procedure in reverse order. ^ Verify ignition switch lock cylinder operation. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > Customer Interest for Starter Cable: > 01-21-8 > Oct > 01 > Starting System - No Crank/No Start Condition Starter Cable: Customer Interest Starting System - No Crank/No Start Condition Article No. 01-21-8 10/29/01 ^ DRIVEABILITY - NO CRANK, NO START - CORROSION OF THE STARTER CABLE B+ TERMINAL AT THE STARTER SOLENOID ^ STARTING - NO CRANK, NO START - CORROSION OF THE STARTER CABLE B+ TERMINAL AT THE STARTER SOLENOID FORD: 1997-2000 F-150 ISSUE Some vehicles may exhibit a no crank, no start condition. This may be caused by corrosion of the starter cable B+ terminal at the starter solenoid due to a reaction between dissimilar metals (steel nut used to attach the battery cable to a brass stud on the starter). ACTION Whenever the starter or harness is replaced, the new brass/tin plated nut (W706414-S413) replaces the old service steel nut. Follow the appropriate model year Workshop Manual for harness and starter replacement procedures. NOTE IF CORROSION HAS DAMAGED THE STARTER CABLE END (CRACKED, ERODED METAL), THE APPROVED PROCEDURE IS TO REPLACE THE HARNESS. DO NOT ATTEMPT TO REPLACE THE STARTER CABLE EYELET. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 601300, 603300 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Starter Cable: > 01-21-8 > Oct > 01 > Starting System - No Crank/No Start Condition Starter Cable: All Technical Service Bulletins Starting System - No Crank/No Start Condition Article No. 01-21-8 10/29/01 ^ DRIVEABILITY - NO CRANK, NO START - CORROSION OF THE STARTER CABLE B+ TERMINAL AT THE STARTER SOLENOID ^ STARTING - NO CRANK, NO START - CORROSION OF THE STARTER CABLE B+ TERMINAL AT THE STARTER SOLENOID FORD: 1997-2000 F-150 ISSUE Some vehicles may exhibit a no crank, no start condition. This may be caused by corrosion of the starter cable B+ terminal at the starter solenoid due to a reaction between dissimilar metals (steel nut used to attach the battery cable to a brass stud on the starter). ACTION Whenever the starter or harness is replaced, the new brass/tin plated nut (W706414-S413) replaces the old service steel nut. Follow the appropriate model year Workshop Manual for harness and starter replacement procedures. NOTE IF CORROSION HAS DAMAGED THE STARTER CABLE END (CRACKED, ERODED METAL), THE APPROVED PROCEDURE IS TO REPLACE THE HARNESS. DO NOT ATTEMPT TO REPLACE THE STARTER CABLE EYELET. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 601300, 603300 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Drive/Bendix > Component Information > Description and Operation Starter Drive/Bendix: Description and Operation The starter drive: - is operated by the starter solenoid. - engages the flywheel to turn the engine. - has an internal over-running clutch to disengage the starter motor when the engine starts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Drive/Bendix > Component Information > Testing and Inspection > Starter Drive Test Starter Drive/Bendix: Testing and Inspection Starter Drive Test 1. Remove the starter motor. 2. Secure the starter motor in a vise. 3. Connect the battery ground cable of a fully charged battery to the case of the starter motor. 4. Touch the positive lead from the battery to the S-terminal and verify that the starter drive ejects. CAUTION: Do not leave the positive lead of the battery connected to the starter motor S-terminal for more than ten seconds. 5. Remove the positive lead from the starter motor. The ejected starter drive should return to its original position. 6. If the starter drive does not eject and return to position, replace the starter motor. 7. Check the starter drive. It should turn freely in one direction, and positively engage to the armature when turned in the opposite direction. If not as specified, replace the starter motor. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Drive/Bendix > Component Information > Testing and Inspection > Starter Drive Test > Page 7615 Starter Drive/Bendix: Testing and Inspection Starter Drive and Flywheel Ring Gear Inspection 1. Check the wear patterns on the (A) starter drive and the (B) flywheel ring gear. If the wear pattern is normal, install the starter motor. 2. If the (A) starter drive gear and the flywheel ring gear are not fully meshing or the gears are (B) milled or damaged, replace the starter motor. Replace the flywheel ring gear. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Specifications Starter Relay: Specifications Starter Motor Solenoid Relay Switch Bolts ........................................................................................................................................ 7-9 N.m (61-79 Lb-In) Starter Motor Solenoid Relay Switch Terminal Nuts .......................................................................................................................... 5-7 N.m (44-62 Lb-In) Starter Motor Solenoid Relay Switch Cable Nuts .......................................................................................................................... 5-11.2 N.m (45-99 Lb-In) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Description and Operation > Automatic Transmission Starter Relay: Description and Operation Automatic Transmission The starter motor solenoid relay switch: - controls current to the starter solenoid. - is engaged by the ignition switch. - connects the battery to the starter motor. The digital TR sensor prevents starter motor engagement unless the transmission is in the NEUTRAL or PARK position. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Description and Operation > Automatic Transmission > Page 7621 Starter Relay: Description and Operation Manual Transmission The starter motor solenoid relay switch: - controls current to the starter solenoid. - is engaged by the ignition switch. - connects the battery to the starter motor. The Clutch Pedal Position (CPP) switch prevents starter motor engagement unless the clutch pedal is pressed. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Description and Operation > Page 7622 Starter Relay: Testing and Inspection Use the 73 Digital Multimeter to check for continuity between terminal 85 and all other terminals. If resistance is 5 ohms or less between terminal 85 and any other terminal, replace the relay. If resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay terminals 86 and 30 directly to the positive battery terminal. Use the 73 Digital Multimeter set in the volts position to check for voltage at terminal 87A. If battery voltage is not indicated, replace the relay. If battery voltage is indicated, connect a third jumper wire to terminal 85 and ground the jumper wire to a know good ground. Check for voltage at terminal 87. If battery voltage is not indicated, replace the relay. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Description and Operation > Page 7623 Starter Relay: Service and Repair REMOVAL WARNING: WHEN CARRYING OUT MAINTENANCE ON THE STARTING SYSTEM BE AWARE THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE PROTECTIVE CAPS ARE IN PLACE WHEN MAINTENANCE IS COMPLETE. FAILURE TO FOLLOW THIS PROCEDURE MAY RESULT IN PERSONAL INJURY. 1. Disconnect the battery ground cable. 2. Remove the insulator. 3. Disconnect the starter motor solenoid relay switch wires and cables. - Disconnect the engine control sensor wiring terminal. - Remove the starter motor solenoid relay switch terminal nuts. - Remove the wiring. 4. Remove the starter motor solenoid relay switch. - Remove the bolts. - Remove the starter motor solenoid relay switch. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Description and Operation > Page 7624 WARNING: WHEN CARRYING OUT MAINTENANCE ON THE STARTING SYSTEM BE AWARE THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE PROTECTIVE CAPS ARE IN PLACE WHEN MAINTENANCE IS COMPLETE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY. 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Technical Service Bulletins > Customer Interest for Starter Solenoid: > 01-21-8 > Oct > 01 > Starting System - No Crank/No Start Condition Starter Solenoid: Customer Interest Starting System - No Crank/No Start Condition Article No. 01-21-8 10/29/01 ^ DRIVEABILITY - NO CRANK, NO START - CORROSION OF THE STARTER CABLE B+ TERMINAL AT THE STARTER SOLENOID ^ STARTING - NO CRANK, NO START - CORROSION OF THE STARTER CABLE B+ TERMINAL AT THE STARTER SOLENOID FORD: 1997-2000 F-150 ISSUE Some vehicles may exhibit a no crank, no start condition. This may be caused by corrosion of the starter cable B+ terminal at the starter solenoid due to a reaction between dissimilar metals (steel nut used to attach the battery cable to a brass stud on the starter). ACTION Whenever the starter or harness is replaced, the new brass/tin plated nut (W706414-S413) replaces the old service steel nut. Follow the appropriate model year Workshop Manual for harness and starter replacement procedures. NOTE IF CORROSION HAS DAMAGED THE STARTER CABLE END (CRACKED, ERODED METAL), THE APPROVED PROCEDURE IS TO REPLACE THE HARNESS. DO NOT ATTEMPT TO REPLACE THE STARTER CABLE EYELET. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 601300, 603300 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Technical Service Bulletins > Customer Interest for Starter Solenoid: > 00-23-8 > Nov > 00 > Starter Solenoid - No Crank/No Start Condition Starter Solenoid: Customer Interest Starter Solenoid - No Crank/No Start Condition Article No. 00-23-8 11/13/00 ^ DRIVEABILITY - NO CRANK/NO START - MOISTURE FREEZES IN STARTER SOLENOID IN TEMPERATURES BELOW - 12 DEGREES C (10 DEGREES F) ^ ELECTRICAL - NO CRANKING START - MOISTURE FREEZES IN STARTER SOLENOID IN TEMPERATURES BELOW - 12 DEGREES C (10 DEGREES F) FORD: 1997-2000 F-150, F-250 LD ISSUE Some vehicles may exhibit a no crank/no start condition in temperatures below -12°C (10°F). This may be caused by moisture in the starter solenoid resulting in frozen starter solenoid electrical contacts. ACTION To prevent the possibility of moisture entering the starter under the solenoid and contaminating the electrical contacts, replace the starter solenoid with a revised solenoid and gasket for improved sealing. SERVICE PROCEDURE NOTE PERFORM ALL NORMAL ELECTRICAL DIAGNOSTICS BEFORE PROCEEDING WITH STARTER REMOVAL. REFER TO THE APPROPRIATE WORKSHOP MANUAL, SECTION 303-06, TO CHECK BATTERY AND ELECTRICAL CONNECTION CONDITION. 1. Remove starter from vehicle (refer to the Workshop Manual, Section 303-06). 2. Remove solenoid from starter by removing motor terminal shunt nut. Retain nut. 3. Completely loosen the two (2) attaching screws at the base of the solenoid. Screws are captured by motor housing. 4. Remove solenoid by sliding away from motor housing, then unhooking the solenoid rod from the motor lever. 5. Attach the revised Starter Solenoid (F8ZZ-11390-BA) which has a gasket included by reversing the steps above. 6. Hook the revised solenoid rod into the lever "fork," taking care that the solenoid terminal with silver connecting strap is closest to the motor housing. 7. Install solenoid screws and torque to 7.25 +/- 2.25 Nm (64 +/- 20 LB-IN). 8. Install motor terminal nut and torque to 12 +/- 3 Nm (106 +/- 25 LB-IN). 9. Reinstall starter into vehicle. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under the Provisions Of Bumper to Bumper Warranty Coverage Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Technical Service Bulletins > Customer Interest for Starter Solenoid: > 00-23-8 > Nov > 00 > Starter Solenoid - No Crank/No Start Condition > Page 7637 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 203000, 203200, 601300, 603300 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Starter Solenoid: > 01-21-8 > Oct > 01 > Starting System No Crank/No Start Condition Starter Solenoid: All Technical Service Bulletins Starting System - No Crank/No Start Condition Article No. 01-21-8 10/29/01 ^ DRIVEABILITY - NO CRANK, NO START - CORROSION OF THE STARTER CABLE B+ TERMINAL AT THE STARTER SOLENOID ^ STARTING - NO CRANK, NO START - CORROSION OF THE STARTER CABLE B+ TERMINAL AT THE STARTER SOLENOID FORD: 1997-2000 F-150 ISSUE Some vehicles may exhibit a no crank, no start condition. This may be caused by corrosion of the starter cable B+ terminal at the starter solenoid due to a reaction between dissimilar metals (steel nut used to attach the battery cable to a brass stud on the starter). ACTION Whenever the starter or harness is replaced, the new brass/tin plated nut (W706414-S413) replaces the old service steel nut. Follow the appropriate model year Workshop Manual for harness and starter replacement procedures. NOTE IF CORROSION HAS DAMAGED THE STARTER CABLE END (CRACKED, ERODED METAL), THE APPROVED PROCEDURE IS TO REPLACE THE HARNESS. DO NOT ATTEMPT TO REPLACE THE STARTER CABLE EYELET. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 601300, 603300 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Starter Solenoid: > 00-23-8 > Nov > 00 > Starter Solenoid No Crank/No Start Condition Starter Solenoid: All Technical Service Bulletins Starter Solenoid - No Crank/No Start Condition Article No. 00-23-8 11/13/00 ^ DRIVEABILITY - NO CRANK/NO START - MOISTURE FREEZES IN STARTER SOLENOID IN TEMPERATURES BELOW - 12 DEGREES C (10 DEGREES F) ^ ELECTRICAL - NO CRANKING START - MOISTURE FREEZES IN STARTER SOLENOID IN TEMPERATURES BELOW - 12 DEGREES C (10 DEGREES F) FORD: 1997-2000 F-150, F-250 LD ISSUE Some vehicles may exhibit a no crank/no start condition in temperatures below -12°C (10°F). This may be caused by moisture in the starter solenoid resulting in frozen starter solenoid electrical contacts. ACTION To prevent the possibility of moisture entering the starter under the solenoid and contaminating the electrical contacts, replace the starter solenoid with a revised solenoid and gasket for improved sealing. SERVICE PROCEDURE NOTE PERFORM ALL NORMAL ELECTRICAL DIAGNOSTICS BEFORE PROCEEDING WITH STARTER REMOVAL. REFER TO THE APPROPRIATE WORKSHOP MANUAL, SECTION 303-06, TO CHECK BATTERY AND ELECTRICAL CONNECTION CONDITION. 1. Remove starter from vehicle (refer to the Workshop Manual, Section 303-06). 2. Remove solenoid from starter by removing motor terminal shunt nut. Retain nut. 3. Completely loosen the two (2) attaching screws at the base of the solenoid. Screws are captured by motor housing. 4. Remove solenoid by sliding away from motor housing, then unhooking the solenoid rod from the motor lever. 5. Attach the revised Starter Solenoid (F8ZZ-11390-BA) which has a gasket included by reversing the steps above. 6. Hook the revised solenoid rod into the lever "fork," taking care that the solenoid terminal with silver connecting strap is closest to the motor housing. 7. Install solenoid screws and torque to 7.25 +/- 2.25 Nm (64 +/- 20 LB-IN). 8. Install motor terminal nut and torque to 12 +/- 3 Nm (106 +/- 25 LB-IN). 9. Reinstall starter into vehicle. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under the Provisions Of Bumper to Bumper Warranty Coverage Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Starter Solenoid: > 00-23-8 > Nov > 00 > Starter Solenoid No Crank/No Start Condition > Page 7647 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 203000, 203200, 601300, 603300 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Technical Service Bulletins > Page 7648 Starter Solenoid: Specifications Starter Solenoid B-Terminal Nut ...................................................................................................................................................... 10-14 N.m (7-10 Lb-Ft) Starter Solenoid M-Terminal Nut ..................................................................................................................................................... 10-14 N.m (7-10 Lb-Ft) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Technical Service Bulletins > Page 7649 Starter Solenoid: Description and Operation The starter drive: - is operated by the starter solenoid. - engages the flywheel to turn the engine. - has an internal over-running clutch to disengage the starter motor when the engine starts. The starter solenoid: - is an electromagnet. - engages the starter drive to the flywheel. - when energized, the contacts close, connecting the battery to the starter motor. This causes the starter motor to turn the starter drive. - is kept in the energized condition by a hold-in winding until the starter switch is released. When the ignition switch is turned to the START position, the starter motor solenoid relay switch is energized, connecting the battery to the starter solenoid. The starter solenoid moves the drive lever and pin to engage the starter drive with the flywheel ring gear and connects the battery to the starter motor. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions Circuit Breaker: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 7655 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 7656 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 7657 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 7658 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 7659 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 7660 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 7661 Circuit Breaker: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 7662 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 7663 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 7664 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 7665 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 7666 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 7667 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions Electrical Accessory Panel: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7672 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7673 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7674 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7675 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7676 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7677 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7678 Electrical Accessory Panel: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7679 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7680 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7681 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7682 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7683 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7684 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7693 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7694 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7695 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7696 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7697 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7698 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7699 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7700 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7706 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7707 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7708 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7709 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7710 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7711 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7712 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7713 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box Fuse: Locations Battery Junction Box Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box > Page 7718 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box > Page 7719 Fuse: Locations Central Junction Box Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box > Page 7720 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7723 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7724 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7725 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7726 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7727 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7728 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7729 Fuse: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7730 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7731 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7732 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7733 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7734 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7735 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box Fuse: Application and ID Battery Junction Box Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box > Page 7738 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box > Page 7739 Fuse: Application and ID Central Junction Box Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box > Page 7740 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7745 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7746 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7747 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7748 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7749 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7750 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7751 Fuse Block: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7752 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7753 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7754 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7755 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7756 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7757 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7758 Fuse Block: Connector Views Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7759 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 7763 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 7767 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7772 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7773 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7774 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7775 Multiple Junction Connector: Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7776 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7777 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7778 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7779 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7780 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7781 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7782 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7783 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7784 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7785 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7786 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7787 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7788 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7789 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7790 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7791 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7792 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7793 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7794 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7795 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7796 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 7801 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 7805 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 7811 Relay Box: Diagrams Central Junction Box Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 7812 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 7813 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 7814 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 7815 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 7821 Relay Box: Diagrams Central Junction Box Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 7822 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 7823 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 7824 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 7825 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions Circuit Breaker: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 7831 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 7832 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 7833 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 7834 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 7835 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 7836 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 7837 Circuit Breaker: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 7838 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 7839 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 7840 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 7841 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 7842 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 7843 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions Electrical Accessory Panel: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7848 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7849 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7850 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7851 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7852 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7853 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7854 Electrical Accessory Panel: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7855 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7856 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7857 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7858 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7859 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Diagrams > Diagram Information and Instructions > Page 7860 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 7869 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 7870 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 7871 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 7872 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 7873 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 7874 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 7875 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 7876 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers Technical Service Bulletin # 02-16-4 Date: 020819 Audio System - Whining/Buzzing Noise From Speakers Article No. 02-16-4 08/19/02 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG 1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003 NAVIGATOR 2002 BLACKWOOD MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER 1997-2002 MOUNTAINEER TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line coverage. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7882 NOTE IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE RFI FILTER INSTALLATION. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-7-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 021604AA Diagnose And Install RFI 2.1 Hrs. Filter 1990-1997 Thunderbird/Cougar 021604BA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1999 And 2001 Taurus/Sable 021604CA Diagnose And Install RFI 1.2 Hrs. Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car 021604CB Diagnose And Install RFI 1.6 Hrs. Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car 021604CC Diagnose And Install RFI 2.2 Hrs. Filter 1998-2002 Crown Victoria/Grand Marquis 021604DA Diagnose And Install RFI 1.9 Hrs. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7883 Filter 1998-2002 Town Car 021604EA Diagnose And Install RFI 1.7 Hrs. Filter 1990-1998 Mustang 021604FA Diagnose And Install RFI 1.6 Hrs. Filter 1990-1998 Mustang 021604GA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1994 Continental 021604HA Diagnose And Install RFI 1.6 Hrs. Filter 1990 Escort 021604IA Diagnose And Install RFI 0.8 Hr. Filter 1991-1996 Escort Tracer 021604IB Diagnose And Install RFI 1.6 Hrs. Filter 1997 Escort/Tracer 021604JA Diagnose And Install RFI 0.8 Hr. Filter 1997 Contour/Mystique 021604JB Diagnose And Install RFI 1.8 Hrs. Filter 1998-1999 Contour/Mystique 021604KA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1992 Mark VII 021604LA Diagnose And Install RFI 0.8 Hr. Filter 1990-1992 Probe 021604LB Diagnose And Install RFI 1.8 Hrs. Filter 1993-1997 Probe 021604MA Diagnose And Install RFI 1.6 Hrs. Filter 1990-2002 Econoline Single Fuel Tank 021604MB Diagnose And Install RFI 2.6 Hrs. Filter 1990-1991 Econoline Both Fuel Tanks 021604NA Diagnose And Install RFI 2.0 Hrs. Filter 1990-1996 Bronco 0216040A Diagnose And Install RFI 1.8 Hrs. Filter 1991-1994 Explorer 0216040B Diagnose And Install RFI 1.5 Hrs. Filter 1995-2002 Explorer 021604PA Diagnose And Install RFI 1.5 Hrs. Filter 1997-2002 Mountaineer 0216040A Diagnose And Install RFI 1.4 Hrs. Filter 1995-2002 Windstar 021604RA Diagnose And Install RFI 1.9 Hrs. Filter 1993-2002 Villager Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7884 021604SA Diagnose And Install RFI 1.7 Hrs. Filter 1997-2003 Expedition/Navigator 021604TA Diagnose And Install RFI 1.3 Hrs. Filter 1990-1997 Ranger Standard Cab 021604TB Diagnose And Install RFI 1.8 Hrs. Filter 1990-1997 Ranger Super Cab 021604TC Diagnose And Install RFI 1.8 Hrs. Filter 1998-2002 Ranger 4X4 021604TD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 Ranger 4X2 021604UA Diagnose And Install RFI 1.5 Hrs. Filter 1990-1997 Aerostar 021604VA Diagnose And Install RFI 1.9 Hrs. Filter 1990 Bronco II 021604WA Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear 021604WB Diagnose And Install RFI 1.4 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front 021604WC Diagnose And Install RFI 2.1 Hrs. Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks 021604WD Diagnose And Install RFI 1.6 Hrs. Filter 1998-2002 F-150 021604XA Diagnose And Install RFI 1.6 Hrs. Filter 2000-2002 Excursion 021604XB Diagnose And Install RFI 1.6 Hrs. Filter 1999-2002 Super Duty F-Series: Front Tank 021604XC Diagnose And Install RFI 1.5 Hrs. Filter 1999-2002 Super Duty F-Series: Rear Tank 021604XD Diagnose And Install RFI 2.7 Hrs. Filter 1999-2002 Super Duty F-Series: Both Tanks 021604YA Diagnose And Install RFI 0.8 Hr. Filter 2001-2002 Escape Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7885 021604ZA Diagnose And Install RFI 1.9 Hrs. Filter 2002 Blackwood DEALER CODING CONDITION BASIC PART NO. CODE 18B925 42 OASIS CODES: 205000, 207000, 404000, 702000, 702300 Service Procedure 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7886 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7887 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7888 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over solder connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7889 NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank, cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box Fuse: Locations Battery Junction Box Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box > Page 7894 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box > Page 7895 Fuse: Locations Central Junction Box Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Battery Junction Box > Page 7896 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions Fuse: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7899 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7900 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7901 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7902 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7903 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7904 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7905 Fuse: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7906 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7907 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7908 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7909 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7910 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram Information and Instructions > Page 7911 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box Fuse: Application and ID Battery Junction Box Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box > Page 7914 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box > Page 7915 Fuse: Application and ID Central Junction Box Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID > Battery Junction Box > Page 7916 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7921 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7922 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7923 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7924 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7925 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7926 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7927 Fuse Block: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7928 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7929 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7930 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7931 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7932 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7933 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7934 Fuse Block: Connector Views Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 7935 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 7939 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 7943 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7948 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7949 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7950 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7951 Multiple Junction Connector: Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7952 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7953 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7954 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7955 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7956 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7957 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7958 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7959 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7960 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7961 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7962 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7963 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7964 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7965 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7966 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7967 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7968 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7969 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7970 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7971 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C119 > Page 7972 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection Micro ISO Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection > Page 7977 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection Mini ISO Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection > Page 7981 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 7987 Relay Box: Diagrams Central Junction Box Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 7988 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 7989 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 7990 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 7991 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 7997 Relay Box: Diagrams Central Junction Box Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 7998 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 7999 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 8000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Blower/Flasher Relay Block > Page 8001 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8007 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8008 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8009 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8010 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8011 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8012 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8013 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8014 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8015 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8016 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8017 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8018 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8019 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8020 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8021 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8022 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8023 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8024 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8025 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8026 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8027 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8028 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8029 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8030 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8031 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8032 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8033 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8034 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8035 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8036 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8037 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8038 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8039 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8040 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8041 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8042 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8043 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8044 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8045 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8046 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8047 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8048 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8049 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8050 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8051 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8052 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8053 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8054 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8055 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8056 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8057 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8058 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8059 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8060 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8061 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8062 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8063 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8064 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8065 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8066 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8067 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8068 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8069 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8070 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8071 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8072 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8073 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8074 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8075 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8076 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8077 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8078 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8079 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8080 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8081 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8082 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8083 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8084 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8085 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8086 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8087 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8088 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8089 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8090 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8091 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8092 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8093 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8094 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8095 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8096 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8097 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8098 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8099 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8100 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8101 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 8102 Alignment: Specifications Caster LH ........................................................................................................................................................ ....................................................... 4.6° ± 1.0° RH ............................................................................. .................................................................................................................................. 5.3° ± 1.0° Total/Split ............................................................................................................................................. ..................................................... -0.7° ± 0.7° Camber LH ........................................................................................................................................................ ...................................................... -0.1° ± 0.7° RH ............................................................................. ................................................................................................................................ -0.1° ± 0.7° Total/Split ............................................................................................................................................. ......................................................... 0° ± 0.7° Toe (Positive Value Is Toe-In, Negative Value Is Toe-Out) LH ........................................................................................................................................................ ................................................... 0.10° ± 0.15° RH ............................................................................. .............................................................................................................................. 0.10° ± 0.15° Total/Split ............................................................................................................................................. .................................................. 0.20° ± 0.25° Dogtracking - Max. (Centerline Of Front Tires Compared To Centerline Of Rear Tires) .......................................................................................................................................... 30 mm (1.2 inch) Clear Vision (Negative Value Is Counterclockwise) ......................................................................................................................................... -0.7 ± 3.0° Vehicle Ride Height Front .................................................................................................................................................... ............... 113 mm ± 19 mm (4.4 in. ± 0.75 in.) Rear ........................................................................... ........................................................................................................... 150-205 mm (5.9-8.1 in.) Vehicle Lean (Side-to-Side Height Differences) Front - Maximum ................................................................................................................................. ................................................ 12 mm (0.5 in.) Rear - Maximum ........................................................ ........................................................................................................................ 19 mm (0.75 in.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 8103 Alignment: Description and Operation WHEEL ALIGNMENT ANGLES Caster and camber are adjusted by means of adjustment slots cut into the upper control arm mounting brackets. Toe is adjusted by the use of the front wheel spindle tie rod adjusting sleeve. Negative and Positive Camber CAMBER Negative and Positive Camber Camber is the vertical tilt of the wheel when viewed from the front. Camber can be positive or negative and has a direct effect on tire wear. Caster And Frame Angle CASTER Caster is the deviation from vertical of an imaginary line drawn through the ball joints when viewed from the side. The caster specifications will give the vehicle the best directional stability characteristics when loaded and driven. The caster setting is not related to tire wear. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 8104 Caster And Frame Angle Negative Toe (Toe Out) TOE The vehicle toe setting: ^ affects tire wear and directional stability. ^ must be checked after adding after-market equipment, such as a snowplow or body. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 8105 RIDE HEIGHT Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 8106 Wheel Track WHEEL TRACK Dogtracking DOGTRACKING Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily crowned roads can give the illusion of dogtracking. WANDER Wander is the tendency of the vehicle to require frequent, random left and right steering wheel corrections to maintain a straight path down a level road. SHIMMY Shimmy, as observed by the driver, is large, consistent, rotational oscillations of the steering wheel resulting from large, side-to-side (lateral) tire/wheel movements. Shimmy is usually experienced near 64 km/h (40 mph), and can begin or be amplified when the tire contacts pot holes or irregularities in the road surface. NIBBLE Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with various road surfaces and observed by the driver as small rotational oscillations of the steering wheel. POOR RETURNABILITY/STICKY STEERING Poor returnability and sticky steering is used to described the poor return of the steering wheel to center after a turn or the steering correction is completed. DRIFT/PULL Pull is a tugging sensation, felt by the hands on the steering wheel, that must be overcome to keep the vehicle going straight. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 8107 Drift describes what a vehicle with this condition does with hands off the steering wheel. ^ A vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-ahead path and require constant steering input in the opposite direction to counteract the effect. ^ Drift/pull may be induced by conditions external to the vehicle (i.e., wind, road camber). POOR GROOVE FEEL Poor groove feel is characterized by little or no buildup of turning effort felt in the steering gear as the wheel is rocked slowly left and right within very small turns around center or straight-ahead (under 20 degrees of steering wheel turn). Efforts may be said to be "flat on center. " ^ Under 20 degrees of turn, most of the turning effort that builds up comes from the mesh of gear teeth in the steering gear. In this range, the steering wheel is not yet turned enough to feel the effort from the self-aligning forces at the road wheel or tire patch. ^ In the diagnosis of a roadability problem, it is important to understand the difference between wander and poor groove feel. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Caster and Camber Alignment: Service and Repair Caster and Camber 1. Loosen the nuts to a point where the upper suspension arm joints are snug. 2. NOTE: A pry bar can be used between the upper control arm and the frame pocket to aid in moving the arm. To increase caster and camber, use the following steps. 1. To increase caster, move the front of the upper control arm outboard and move the rear of the upper control arm inboard. 2. To increase camber, move the upper control arm outboard equally. 3. To decrease caster and camber, use the following steps. 1. To decrease caster, move the front of the upper control arm inboard and move the rear of the upper control arm outboard. 2. To decrease camber, move the upper control arm inboard equally. 4. NOTE: Each increment of the notches on the frame pocket represents 0.3 degree. Set the caster and camber to specifications. ^ If a caster increase of 0.9 degree is required, move the front of the upper control arm outboard by 3 notches and move the rear of the upper control arm inboard by 3 notches. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Caster and Camber > Page 8110 5. Tighten the nuts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Caster and Camber > Page 8111 Alignment: Service and Repair Toe 1. Start the engine and center the steering wheel. 2. Turn the engine off, and hold the steering wheel in the "straight forward" position by attaching a rigid link from the steering wheel to the brake pedal. 3. Check the toe settings; follow the alignment rack manufacturer's instructions. 4. Hold the tie rod end while loosening the nuts. ^ Clean and lubricate the steering linkage and tie rod end threads. 5. Rotate the front wheel spindle tie rod adjusting sleeve to the desired position. 6. Tighten the nuts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Caster and Camber > Page 8112 7. Recheck the toe settings; follow the alignment rack manufacturer's instructions. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations Compressor/Pump Relay: Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 8118 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 8119 Compressor/Pump Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 8120 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations Suspension Control Module: Locations An A-to-Z electrical components location list can be viewed at Vehicle/Locations. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations > Page 8124 Suspension Control Module: Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair Steering Angle Sensor: Service and Repair Removal CAUTION: The steering column must be in the locked position, or the lower end of the column wired in such a way that the steering column does not rotate, resulting in damage to the air bag sliding, contact. NOTE: Discard the upper intermediate shaft to steering column shaft bolt upon removal. Do not reuse; replace with new bolts. 1. Remove the bolt retaining the upper shaft assembly U-joint to the steering column center shaft. 2. Remove the shock absorber electronic steering sensor. 1. Disconnect the electrical connector. 2. Remove the screws. 3. Remove the shock absorber electronic steering sensor. 3. Remove the sensor ring. 1. Remove the steering column lower bearing spring. 2. Remove the sensor ring. Installation 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Page 8130 2. Install the shock absorber electronic steering sensor. 1. Position the shock absorber electronic steering sensor. 2. Install the screws. 3. Connect the electrical connector. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair Steering Angle Sensor: Service and Repair Removal CAUTION: The steering column must be in the locked position, or the lower end of the column wired in such a way that the steering column does not rotate, resulting in damage to the air bag sliding, contact. NOTE: Discard the upper intermediate shaft to steering column shaft bolt upon removal. Do not reuse; replace with new bolts. 1. Remove the bolt retaining the upper shaft assembly U-joint to the steering column center shaft. 2. Remove the shock absorber electronic steering sensor. 1. Disconnect the electrical connector. 2. Remove the screws. 3. Remove the shock absorber electronic steering sensor. 3. Remove the sensor ring. 1. Remove the steering column lower bearing spring. 2. Remove the sensor ring. Installation 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Page 8135 2. Install the shock absorber electronic steering sensor. 1. Position the shock absorber electronic steering sensor. 2. Install the screws. 3. Connect the electrical connector. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Specifications Suspension Mode Switch: Specifications TORQUE SPECIFICATIONS Air Suspension Switch Bracket Bolt ............................................................................................................................... 10.2-13.8 Nm (91-123 inch lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Specifications Center Link: Specifications TORQUE SPECIFICATIONS Center Link Castellated Nut ..................................................................................................................................................... 77-103 Nm (57-76 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Specifications > Page 8143 Center Link: Service and Repair Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the steering sector shaft arm drag link castellated nuts. 1. Remove the cotter pins. 2. Remove the castellated nuts. 3. Remove the two inner tie rods from the steering sector shaft arm drag link. 4. Remove the steering sector shaft arm drag link castellated nut. 1. Remove the cotter pin. 2. Remove the nut. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Specifications > Page 8144 5. Using the Pitman Arm Puller, separate the steering sector shaft arm drag link. 6. Remove the steering sector shaft arm drag link castellated nut. 1. Remove the cotter pin. 2. Remove the nut. 7. Using the Pitman Arm Puller, separate the steering sector shaft arm drag link. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Specifications > Page 8145 1. Follow the removal procedure in reverse order. 2. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Specifications > Page 8146 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Service and Repair Idler Arm: Service and Repair Special Tool(s) Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the steering sector shaft arm drag link castellated nut. 1. Remove the cotter pin. 2. Remove the nut. 3. Use the Pitman Arm Puller to separate the steering sector shaft arm drag link. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Service and Repair > Page 8150 4. Remove the steering idler arm and bracket. 1. Remove the two bolts. 2. Remove the steering idler arm and bracket. Installation 1. Follow the removal procedure in reverse order. 2. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Idler Arm > Component Information > Service and Repair > Page 8151 Special Tool Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Service and Repair Pitman Arm: Service and Repair Special Tool(s) Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the skid plate. 1. Remove the six skid plate bolts. 2. Remove the skid plate. 3. Slide back the plastic cover from the intermediate steering shaft to the steering gear. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Service and Repair > Page 8155 4. Remove the intermediate steering shaft bolt and remove the intermediate steering shaft from the steering gear. 5. Remove the steering sector shaft arm drag link castellated nut. 1. Remove the cotter pin. 2. Remove the castellated nut. 6. Use the Pitman Arm Puller to separate the steering sector shaft arm drag link. 7. Scribe alignment marks between the steering gear sector shaft and steering gear sector shaft arm. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Service and Repair > Page 8156 8. Remove the steering gear sector shaft arm to the sector shaft nut. 9. Remove the steering gear to frame mounting bolts. 10. Disconnect the steering gear. 1. Position the steering gear. 2. Slide back the spring clamp. 3. Remove the return line, allowing the fluid to drain. 11. Remove the pressure line from the steering gear, and remove the steering gear from the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Service and Repair > Page 8157 12. Remove the steering gear sector shaft arm. ^ Secure the steering gear in a vise, then using the Pitman Arm Puller, remove the steering gear sector shaft arm. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Service and Repair > Page 8158 1. NOTE: The steering gear sector shaft arm to sector shaft nut must be installed and tightened to specifications prior to installation of the steering gear for clearance purposes. Follow the removal procedure in reverse order. 2. If equipped with air suspension, reactivate the system by turning on the air suspension switch. 3. Fill, bleed and leak check the system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Service and Repair > Page 8159 Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair Power Steering Bleeding: Service and Repair Special Tools CAUTION: If the air is not purged from the power steering system correctly, premature power steering pump failure could result. This condition can occur on pre-delivery vehicles with evidence of aerated fluid or on vehicles that have had steering component repairs. 1. NOTE: A whine heard from the power steering pump may be caused by air in the system. The power steering purge procedure must be performed prior to any component repair for which power steering noise complaints are accompanied by evidence of aerated fluid. Remove the reservoir cap. Check the fluid. ^ Use Motorcraft MERCON Multi-Purpose ATF XT-2-QDX or MERCON equivalent. 2. Tightly insert the stopper of the vacuum pump into the reservoir. 3. Start the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair > Page 8164 4. Apply maximum vacuum and maintain it for a minimum of three minutes with the engine speed set at idle. 5. Release the vacuum and remove the vacuum pump. 6. CAUTION: Do not overfill the reservoir. Fill the reservoir. ^ Use Motorcraft MERCON Multi-Purpose ATF XT-2-QDX or MERCON equivalent. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair > Page 8165 7. Reinstall the vacuum pump. Apply and maintain maximum vacuum. 8. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump could occur. Cycle the steering wheel fully to the left and right every 30 seconds for approximately five minutes. 9. Stop the engine, release the vacuum, and remove the vacuum pump. 10. Install the reservoir cap. 11. Check for fluid leaks at all of the connections. If the power steering fluid shows signs of air, repeat this procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage Power Steering Fluid: Technical Service Bulletins Steering - Mercon V(R) Fluid Usage TSB 07-1-7 01/22/07 MERCON(R) ATF REPLACED BY MERCON(R) V AS A SERVICE FLUID FOR SOME POWER STEERING SYSTEMS FORD: 1996-1997 Thunderbird 1996-2007 Crown Victoria, Mustang, Taurus 1998-2003 Escort 2000-2007 Focus 2002-2005 Thunderbird 2005-2006 Ford GT 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1996-1997 Aerostar 1996-2007 E-Series, Explorer, Ranger 1997-2004 F-53 Motorhome Chassis 1997-2007 Expedition, F-150, F-Super Duty 1998-2003 Windstar 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2007 Escape 2004-2007 Freestar 2005-2007 Escape Hybrid 1996-1997 Cargo 1996-1998 L-Series 1996-1999 F- B-Series 2000-2007 F-650, F-750 2006-2007 Low Cab Forward LINCOLN: 1996-1998 Mark VIII 1996-1999 Continental 1996-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX MERCURY: 1996-1997 Cougar 1996-2005 Sable 1996-2007 Grand Marquis 1999-2002 Cougar 2003-2004 Marauder 2005-2007 Montego 2006-2007 Milan 1997-2007 Mountaineer 1998-2002 Villager 2004-2007 Monterey 2005-2007 Mariner Hybrid, Mariner ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid for power steering systems originally requiring MERCON(R). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage > Page 8170 ACTION Beginning immediately all power steering applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will continue until remaining inventory has been depleted. SERVICE PROCEDURE Service power steering Systems requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. CAUTION APPLICATIONS RECOMMENDING TYPE F AUTOMATIC TRANSMISSION AND POWER STEERING FLUID MUST CONTINUE TO USE THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE Parts Block WARRANTY STATUS: Information Only Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 8171 Power Steering Fluid: Specifications Use Motorcraft MERCON(r) Multi-Purpose ATF, XT-2-QDX or equivalent MERCON(r) approved fluid. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Page 8172 Power Steering Fluid: Service Precautions CAUTION: Use only manufacturer recommended Power Steering Fluid or system damage may result. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Specifications Power Steering Fluid Cooler: Specifications TORQUE SPECIFICATIONS Power Steering Fluid Cooler Bolts ...................................................................................................................................... 8.9-12 Nm (80-107 inch lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Specifications > Page 8176 Power Steering Fluid Cooler: Service and Repair Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so may result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. If equipped, remove the skid plate. 1. Remove the bolts. 2. Remove the skid plate. 3. Remove the lower radiator air deflector. 1. Remove the three screws. 2. Remove the five push clips. 3. Remove the lower radiator air deflector. 4. Disconnect the hoses. 1. Compress and move the hose clamps. 2. Disconnect the hoses. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Specifications > Page 8177 5. Remove the power steering fluid cooler. 1. Remove the bolts. 2. Remove the power steering fluid cooler. Installation 1. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Follow the removal procedure in reverse order. 2. Fill and leak check the system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Specifications Power Steering Fluid Reservoir: Specifications TORQUE SPECIFICATIONS Reservoir Bracket Upper Bolts ............................................................................................................................................... 9-12 Nm (80-107 inch lbs.) Reservoir Bracket Bolts To Exhaust Manifold .......................................................................................................................... 68-92 Nm (50-68 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Specifications > Page 8181 Power Steering Fluid Reservoir: Service and Repair Removal 1. Remove the engine air cleaner assembly. 2. Drain the power steering fluid reservoir. 3. Disconnect the power steering hoses. 1. Compress and move the power steering hose clamps. 2. Disconnect the power steering return hose and the power steering reservoir pump hose. 4. Remove the power steering fluid reservoir and bracket. 1. Remove the reservoir bracket bolts. 2. Remove the power steering fluid reservoir and bracket. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Specifications > Page 8182 1. Follow the removal procedure in reverse order. 2. Fill and leak check the system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications TORQUE SPECIFICATIONS Pressure Hose Fitting .............................................................................................................................................................. 17-23 Nm (12.6-17 ft. lbs.) Return Hose Fitting ................................................................................... .............................................................................. 17-23 Nm (12.6-17 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications > Page 8186 Power Steering Line/Hose: Service and Repair Special Tools Removal 1. Refer to the System View illustration for the hose routing and retention points. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications > Page 8187 Installation 1. When connecting a fitting with a seal ring, the ring must be replaced. The Seal Replacer is used to install the return line connector seal and the pressure line connector seal. 2. Fill and leak check the system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications > Page 8188 Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications Power Steering Pump: Mechanical Specifications OPERATIONAL SPECIFICATIONS Type ..................................................................................................................................................... ........................................................................ CIII TORQUE SPECIFICATIONS Power Steering Pump Lower Bolt .............................................................................................................................................. 20-30 Nm (15-20 ft. lbs.) Power Steering Pump Upper Bolts ............................................................................................................................................. 20-30 Nm (15-20 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications > Page 8193 Power Steering Pump: Pressure, Vacuum and Temperature Specifications OPERATIONAL SPECIFICATIONS Relief Pressure .................................................................................................................................... ............................. 8965-9862 kPa (1300-1400 psi) Max. Pressure @ 74°-80°C (165°-175°F) And Engine At 1500 RPM ............................................................................................................................................................. 1034 kPa (150 psi) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Mechanical Specifications > Page 8194 Power Steering Pump: Capacity Specifications OPERATIONAL SPECIFICATIONS Min. Flow Rate @ 74°-80° C (165°-175°F) Power Steering Analyzer Set At 5,102 KPa (750 Psi) And Engine At Idle .......................................................................................................................................................... 5.3 Liters/Minute (1.4 gpm) Flow Rate @ 74°-84° C (165°-175°F) And Engine At 1500 RPM ................................................................................................................................. 10.6-12 Liters/Minute (2.8-3.2 gpm) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 8195 Power Steering Pump: Application and ID CAUTION: Always use the ID code when ordering service parts. The pump identification code is located on a tag attached to the power steering pump. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 8196 Power Steering Pump: Description and Operation Power Steering Pump NOTE: On early build 4.6L and 5.4L engines there are four bolts mounting the power steering pump to the engine block. The fourth bolt on earlier builds may be discarded upon the replacement of the power steering pump. The CII1 power steering pump has the following features: ^ It is a belt-driven, vane-type, power steering pump. ^ It is mounted directly to the engine block by three bolts. ^ The power steering pump is replaced as an assembly. ^ An identification tag attached to the power steering pump indicates the model number and bar code. Refer to the identification tag when the pump replacement is required. ^ The power steering pump uses a quick connect fitting for the power steering pressure hose. ^ The power steering fluid reservoir is mounted on the LH side of the engine. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump Power Steering Pump: Service and Repair Power Steering Pump Special Tools Removal 1. Remove the engine air cleaner assembly. 2. Remove the drive belt. 3. Disconnect the power steering pressure hose from the steering gear. 4. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle. 5. Disconnect the power steering reservoir pump hose from the power steering pump. ^ Drain the power steering fluid reservoir. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 8199 6. Remove the upper power steering pump bolts. 7. NOTE: Early build 4.6L and 5.4L engines may have two lower power steering pump bolts; the second bolt may be discarded upon removal of the power steering pump. Remove the lower power steering pump bolt and remove the power steering pump. 8. NOTE: Secure the power steering pump in a vise. Remove the power steering pressure hose. 1. Loosen the power steering pressure hose fitting. 2. Remove the power steering pressure hose. Installation 1. Install the power steering seal by stretching the seat over the seal replacer until it is large enough to slip over the tube nut. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 8200 2. Install the power steering pressure hose. 1. Position the power steering pressure hose into the pump. 2. Tighten the pressure hose fitting. 3. Position the power steering pump and loosely install the power steering pump bolts. 4. Tighten the power steering pump upper bolts. 5. Tighten the power steering pump lower bolt. 6. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. 7. Connect the power steering pressure hose to the steering gear. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 8201 8. Connect the power steering reservoir pump hose to the power steering pump. 9. Install the drive belt. 10. Install the engine air cleaner assembly. 11. Fill and leak check the system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pump > Page 8202 Power Steering Pump: Service and Repair Power Steering Pump Pulley Special Tool(s) Removal 1. Remove the power steering pump. 2. Hold the Steering Pump Pulley Remover and rotate the forcing bolt to remove the power steering pump pulley. Installation 1. Thread the forcing bolt into the power steering pump and turn the Steering Pump Pulley Replacer to install the pump pulley. 2. Install the power steering pump. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Tools and Equipment > Power Steering Pump Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Tools and Equipment > Power Steering Pump > Page 8205 Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair Steering Angle Sensor: Service and Repair Removal CAUTION: The steering column must be in the locked position, or the lower end of the column wired in such a way that the steering column does not rotate, resulting in damage to the air bag sliding, contact. NOTE: Discard the upper intermediate shaft to steering column shaft bolt upon removal. Do not reuse; replace with new bolts. 1. Remove the bolt retaining the upper shaft assembly U-joint to the steering column center shaft. 2. Remove the shock absorber electronic steering sensor. 1. Disconnect the electrical connector. 2. Remove the screws. 3. Remove the shock absorber electronic steering sensor. 3. Remove the sensor ring. 1. Remove the steering column lower bearing spring. 2. Remove the sensor ring. Installation 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair > Page 8210 2. Install the shock absorber electronic steering sensor. 1. Position the shock absorber electronic steering sensor. 2. Install the screws. 3. Connect the electrical connector. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Service and Repair Steering Angle Sensor: Service and Repair Removal CAUTION: The steering column must be in the locked position, or the lower end of the column wired in such a way that the steering column does not rotate, resulting in damage to the air bag sliding, contact. NOTE: Discard the upper intermediate shaft to steering column shaft bolt upon removal. Do not reuse; replace with new bolts. 1. Remove the bolt retaining the upper shaft assembly U-joint to the steering column center shaft. 2. Remove the shock absorber electronic steering sensor. 1. Disconnect the electrical connector. 2. Remove the screws. 3. Remove the shock absorber electronic steering sensor. 3. Remove the sensor ring. 1. Remove the steering column lower bearing spring. 2. Remove the sensor ring. Installation 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Service and Repair > Page 8214 2. Install the shock absorber electronic steering sensor. 1. Position the shock absorber electronic steering sensor. 2. Install the screws. 3. Connect the electrical connector. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. - To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming Deactivation Procedure 1. Disconnect the battery ground cable. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the driver air bag module from the vehicle. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set an air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. 4. Connect an air bag simulator to the vehicle harness at the top of the steering column. 5. Disconnect the passenger air bag module electrical connector. 6. Connect an air bag simulator to the vehicle harness. 7. Reconnect the battery ground cable. Reactivation Procedure 1. Disconnect the battery ground cable. WARNING: The air bag simulators must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the air bag simulator from the vehicle harness connector at the top of the steering column. 4. Install the driver air bag module. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. 5. Remove the air bag simulator from the vehicle harness connector at the passenger air bag module. 6. Connect the passenger air bag module electrical connector. 7. Reconnect the battery ground cable. 8. Prove out the system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 8221 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist should be completed following diagnosis or repair of any air bag system concern. 1. Is the connector at the base of the steering column connected? ................................................................................................................................ [ ] 2. Are the air bag modules connected? ............................................................................................... .......................................................................... [ ] 3. Is the Restraints Control Module (RCM) connected? ............................................................................................................................................... [ ] 4. Is the vehicle battery connected? .................................................................................................... .......................................................................... [ ] Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover > Component Information > Specifications Steering Column Cover: Specifications TORQUE SPECIFICATIONS Upper Instrument Panel Steering Column Cover Bolts ............................................................................................................................................................. 2-3 Nm (18-26 inch lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Sector Shaft > Component Information > Specifications Sector Shaft: Specifications TORQUE SPECIFICATIONS Sector Shaft Housing bolts ......................................................................................................................................................... 61-75 Nm (45-55 ft. lbs.) Steering Gear Sector Shaft Arm Nut .................................................................................................................................. 234-316 Nm (173-233 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Specifications Steering Shaft: Specifications TORQUE SPECIFICATIONS Intermediate Shaft Pinch Bolt .................................................................................................................................................... 41-54 Nm (30-40 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Specifications > Page 8232 Steering Shaft: Service and Repair Removal 1. Remove the intermediate shaft. 1. Remove the steering column shaft bolt. 2. Slide the intermediate shaft off of the steering column. 3. Remove the intermediate shaft dash panel seal. 2. Remove the dust shield from the steering gear housing. 3. Remove the intermediate shaft pinch bolt. 4. Slide the intermediate shaft off the steering gear input shaft. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Specifications > Page 8233 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications Steering Wheel: Specifications TORQUE SPECIFICATIONS Steering Wheel Bolt ............................................................................................................................. ...................................... 31-44 Nm (23-32 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications > Page 8237 Steering Wheel: Service and Repair Special Tool(s) Removal WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not repainted. WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 1. NOTE: Make sure the wheels are in the straight-ahead position. Disconnect the battery ground cable and wait at least one minute. 2. Remove the driver air bag module. 3. Remove the steering wheel bolt. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications > Page 8238 4. CAUTION: Removing the steering wheel without using a puller can damage the column bearings. Use the 2-Jaw Puller to remove the steering wheel. 5. Remove and discard the original steering wheel bolt. 6. Remove the steering wheel while routing the wires from the air bag sliding contact through the steering wheel. Installation 1. Follow the removal procedure in reverse order. 2. Connect the battery cable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications > Page 8239 Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Steering - Tie Rod End Inspection Procedures Tie Rod End: Technical Service Bulletins Steering - Tie Rod End Inspection Procedures Article No. 03-15-13 08/04/03 STEERING - TIE ROD END INSPECTION PROCEDURE FORD: 1997-2002 EXPEDITION 1997-2003 F-150 2001-2004 ESCAPE LINCOLN: 1998-2002 NAVIGATOR 2002-2003 BLACKWOOD This article supersedes 03-9-9 to update the vehicle models covered. ISSUE This article is to be used as an updated procedure for inspecting tie rod end wear. ACTION This procedure is designed to supplement the Workshop Manual, as it provides a more detailed tie rod end inspection procedure. SERVICE INFORMATION NOTE FOR ESCAPE VEHICLES, THIS TIE ROD END INSPECTION PROCEDURE SHOULD ONLY BE COMPLETED ON THE OUTER TIE RODS. FOR ESCAPE INNER TIE ROD INSPECTION PROCEDURES, REFER TO WORKSHOP MANUAL SECTION 211-00. Step 1 - Free Play: Check the outer tie rod ends by grasping by hand and push up and down. Check the inner tie rod ends, pushing them front to rear. If any free play is observed in a joint, it is worn and should be replaced. Step 2 - Stud Lash - Free Play: While vehicle is on the ground or on a drive-on hoist, have an assistant rotate the steering wheel rapidly back and forth from 10 o'clock to 2 o'clock to 10 o'clock while observing the inner and outer tie rods. If the outer tie rod ends have any vertical movement or the inner tie rod ends have any horizontal movement, the tie rod end with the observed movement should be replaced. Step 3 - Seal Inspection: Raise the vehicle on a hoist and remove the front wheels. The wheels will need to be turned to the right in order to inspect the passenger side inner tie rod end and to the left to inspect the drivers side inner tie rod end. Inspect all four seals for tears, perforations and wear. If there is any indication of wear or perforations on the seal, that tie rod end should be replaced. Step 4 - Stud Corrosion: For Escape Vehicles - If Squeak is noticed during Step 2, disconnect tie rod from knuckle and articulate stud in socket. If squeak is verified, replace part. While pushing down on seal, at stud end, if corrosion present at contact point at base of stud, replace part. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Steering - Tie Rod End Inspection Procedures > Page 8245 For All Other Vehicles Covered In This Article: Using a wrench, rotate the tie rod end so that the front of the seal on the outer tie rod end is expanded (Figure 1). Using a puffy knife or other hard, flat, dull object, lift the bottom of the seal up, exposing the stud (Figure 2). If any water escapes from the seal in the form of bubbles or in a liquid form, that tie rod end should be replaced. Closely examine the stud for signs of corrosion, especially around the interface with the knuckle. A rag might be needed to clean off any grease on the stud that impairs a good visual inspection. If there is any sign of corrosion, that tie rod end should be replaced. Rotate the tie rod end in the opposite direction to expand the inner tie rod seal. Repeat the inspection procedure used on the outer tie rod. Repeat this entire procedure on the other side of the vehicle. If there is sign of corrosion, that tie rod end should be replaced. NOTE IF ANY TIE ROD ENDS ARE REMOVED, INSPECT THE SEAL AND THE STUD AGAIN NOTING ANY DIFFERENCES IN VISUAL PERCEPTIONS FROM WHEN THE PART WAS ON THE VEHICLE. CHECKING THE STUD AFTER REMOVAL HELPS IMPROVE CONSCIOUSNESS OF ISSUES WHEN INSPECTING PARTS ON VEHICLE. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-9 WARRANTY STATUS: INFORMATION ONLY Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Steering - Tie Rod End Inspection Procedures > Page 8246 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Page 8247 Tie Rod End: Specifications TORQUE SPECIFICATIONS Tie Rod Castellated Nut ........................................................................................................................................................... 77-103 Nm (57-76 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner Tie Rod End: Service and Repair Inner Special Tool(s) Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the tire and wheel assembly. 3. Mark a reference point from the tie rod end to the front wheel spindle tie rod adjusting sleeve. 4. Remove the inner tie rod end castellated nut. 1. Remove the cotter pin. 2. Remove the nut. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner > Page 8250 5. Using the Pitman Arm Puller, separate the tie rod end. 6. Remove the tie rod end. 1. Loosen the toe set jam nut. 2. Remove the tie rod end. ^ Count and record rotations. Installation 1. Follow the removal procedure in reverse order. 2. Inspect and adjust the toe adjustment. 3. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner > Page 8251 Tie Rod End: Service and Repair Outer Special Tool(s) Removal 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Remove the tire and wheel assembly. 3. Mark a reference point from the tie rod end to the front wheel spindle tie rod adjusting sleeve. 4. Remove the outer tie rod castellated nut. 1. Remove the cotter pin. 2. Remove the nut. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner > Page 8252 5. Using the Pitman Arm Puller, separate the tie rod end. 6. Remove the tie rod end. 1. Loosen the toe set jam nut. 2. Remove the tie rod end. ^ Count and record the rotations. Installation 1. Follow the removal procedure in reverse order. 2. Inspect and adjust the toe adjustment. 3. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Lower the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Inner > Page 8253 Tie Rod End: Service and Repair Replacement Removal 1. Remove the outer tie rod end. 2. Remove the front wheel spindle tie rod adjusting sleeve. 1. Loosen the toe set jam nut. 2. Remove the front wheel spindle tie rod adjusting sleeve. ^ Count and record the rotations. Installation 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Service and Repair > Page 8254 Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Front Suspension Balljoint Inspection Job Aid Ball Joint: Specifications Front Suspension Balljoint Inspection Job Aid Front Lower Balljoint Measurement .................................................................................................................................................. Between lower control arm and knuckle Deflection ............................................................................................................................................. ........................................... 0-0.032 in (0-0.8mm) Reference Diagram ............................................................................................................................. ............................................................................. A Front Upper Balljoint Measurement .................................................................................................................................................. Between upper control arm and knuckle Deflection ............................................................................................................................................. ........................................... 0-0.008 in (0-0.2mm) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Front Suspension Balljoint Inspection Job Aid > Page 8260 Reference Diagram ............................................................................................................................. ............................................................................. C Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Front Suspension Balljoint Inspection Job Aid > Page 8261 Ball Joint: Specifications Ball Joint, Lower OPERATIONAL SPECIFICATIONS Ball Joint Radial Play ........................................................................................................................... .................................................. 0.8 mm (1/32 in.) TORQUE SPECIFICATIONS Lower Ball Joint Nut ............................................................................................................................................................ 113-153 Nm (83-112 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Front Suspension Balljoint Inspection Job Aid > Page 8262 Ball Joint: Specifications Ball Joint, Upper OPERATIONAL SPECIFICATIONS Ball Joint Radial Play ........................................................................................................................... .................................................. 0.8 mm (1/32 in.) TORQUE SPECIFICATIONS Upper Ball Joint Castellated Nut .............................................................................................................................................. 77-103 Nm (57-76 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Ball Joint Inspection Ball Joint: Testing and Inspection Ball Joint Inspection 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located behind the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 2. Prior to performing any inspection of the ball joints, inspect the front wheel bearings. 3. Position a safety stand beneath the front suspension lower arm to be tested. 4. While an assistant pulls and pushes the bottom of the tire, observe the relative movement between the lower spindle arm and the front suspension lower arm ball joint. Any movement at or exceeding the specification indicates a worn or damaged lower ball joint. Replace as necessary. 5. While an assistant pulls and pushes the top of the tire, observe the relative movement between the upper spindle arm and the front suspension lower arm ball joint. Movement at or exceeding the specification indicates a worn or damaged upper ball joint. Replace the upper ball joint as necessary. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Ball Joint Inspection > Page 8265 Ball Joint: Testing and Inspection Front Suspension Balljoint Inspection Job Aid Front Lower Balljoint Measurement .................................................................................................................................................. Between lower control arm and knuckle Deflection ............................................................................................................................................. ........................................... 0-0.032 in (0-0.8mm) Reference Diagram ............................................................................................................................. ............................................................................. A Front Upper Balljoint Measurement .................................................................................................................................................. Between upper control arm and knuckle Deflection ............................................................................................................................................. ........................................... 0-0.008 in (0-0.2mm) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Ball Joint Inspection > Page 8266 Reference Diagram ............................................................................................................................. ............................................................................. C Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair Control Arm Bushing: Service and Repair 1. The control arm bushings are not serviced separately. If the bushings require service, the front suspension lower arm or the front suspension upper arm will have to be installed new. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair Rear Knuckle: Service and Repair Removal 1. Remove the wheel hub. 2. Remove the torsion bar cover plate. 1. Remove the retaining bolts. 2. Remove the torsion bar cover plate. 3. Make preliminary adjustment references. 1. Make an alignment mark on the torsion bar and the torsion bar crossmember support. 2. Measure and record the length. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Page 8274 4. Relieve the torsion bar tension. 1. Position the torsion bar tool and the adapters. 2. Tighten the torsion bar tool until the torsion bar adjuster lifts off of the adjustment bolt. 5. CAUTION: The torsion bar adjustment bolt is coated with dry Loctite(R) and must be replaced if it is backed off or removed. Failure to do so can cause the adjustment bolt to loosen up during operation and a loss of vehicle alignment. Remove the torsion bar adjustment bolt and nut. 6. Loosen the torsion bar adjustment tool until the tension is off the torsion bar. 7. If equipped with 4 wheel anti-lock brake system (4WABS), safely reposition the anti-lock sensor wire. 1. Remove the front brake anti-lock sensor wire bracket bolt. 2. Safely reposition the anti-lock sensor wire. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Page 8275 8. Remove the upper ball joint castellated nut. 1. Remove the upper ball joint cotter pin. 2. Remove the upper ball joint castellated nut. 9. Use the Pitman Arm Pullet to separate the front wheel knuckle from the front suspension upper arm. 10. Remove the tie rod end castellated nut. 1. Remove the tie rod end cotter pin. 2. Remove the tie rod end castellated nut. 11. Use the Pitman Arm Puller to separate the tie rod end. ^ Separate the tie rod end from the front wheel knuckle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Page 8276 12. Remove the lower ball joint castellated nut. 1. Remove the lower ball joint cotter pin. 2. Remove the lower ball joint castellated nut. 13. Use the Pitman Arm Puller to separate the front wheel knuckle from the front suspension lower arm. 14. CAUTION: Suspend the front wheel driveshaft and joint with wire. Remove the front wheel knuckle. Installation 1. Install the front suspension arm upper ball joint castellated nut. 1. Position the front wheel knuckle. 2. Install the front suspension arm upper ball joint castellated nut. 3. Install a new cotter pin. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Page 8277 2. Install the front suspension arm lower ball joint castellated nut. 1. Position the front wheel knuckle. 2. Install the front suspension arm lower ball joint castellated nut. 3. Install a new cotter pin. 3. Install the tie rod end castellated nut. 1. Position the tie rod end. 2. Install the tie rod end castellated nut. 3. Install a new cotter pin. 4. CAUTION: The torsion bar adjustment bolt is coated with dry Loctite(R) and must be replaced if it is backed off or removed. Failure to do so can cause the adjustment bolt to loosen up during operation and a loss of vehicle alignment. Preload the torsion bar. 1. Tighten the torsion bar tool until the new adjustment bolt and nut can be installed. 2. Turn the adjustment bolt until preliminary adjustment marks are aligned. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Page 8278 5. Install the torsion bar cover plate. 1. Position the torsion bar cover plate. 2. Install the retaining bolts. 6. Install the wheel hub. 7. If equipped with 4WABS, install the anti-lock sensor wire bracket bolt. 1. Position the anti-lock sensor wire. 2. Install the bolt. 8. Adjust the ride height. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Page 8279 Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations Compressor/Pump Relay: Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 8284 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 8285 Compressor/Pump Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 8286 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations Suspension Control Module: Locations An A-to-Z electrical components location list can be viewed at Vehicle/Locations. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations > Page 8290 Suspension Control Module: Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair Steering Angle Sensor: Service and Repair Removal CAUTION: The steering column must be in the locked position, or the lower end of the column wired in such a way that the steering column does not rotate, resulting in damage to the air bag sliding, contact. NOTE: Discard the upper intermediate shaft to steering column shaft bolt upon removal. Do not reuse; replace with new bolts. 1. Remove the bolt retaining the upper shaft assembly U-joint to the steering column center shaft. 2. Remove the shock absorber electronic steering sensor. 1. Disconnect the electrical connector. 2. Remove the screws. 3. Remove the shock absorber electronic steering sensor. 3. Remove the sensor ring. 1. Remove the steering column lower bearing spring. 2. Remove the sensor ring. Installation 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair > Page 8295 2. Install the shock absorber electronic steering sensor. 1. Position the shock absorber electronic steering sensor. 2. Install the screws. 3. Connect the electrical connector. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Specifications Suspension Mode Switch: Specifications TORQUE SPECIFICATIONS Air Suspension Switch Bracket Bolt ............................................................................................................................... 10.2-13.8 Nm (91-123 inch lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Specifications Stabilizer Link: Specifications TORQUE SPECIFICATIONS Front Stabilizer Bar Link Nut .................................................................................................................................................... 21-29 Nm (15-21 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air Dryer, Suspension Control > Component Information > Specifications Air Dryer: Specifications TORQUE SPECIFICATIONS Compressor Air Drier Hold Down Screw ................................................................................................................................... 2-3 Nm (18-27 inch lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump, Suspension Control > Component Information > Specifications Compressor/Pump: Specifications TORQUE SPECIFICATIONS Air Compressor Bracket Bolts ............................................................................................................................................ 7.6-10.4 Nm (68-88 inch lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump Relay, Suspension Control > Component Information > Locations Compressor/Pump Relay: Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 8313 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 8314 Compressor/Pump Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 8315 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Diagnostic Connector, Suspension > Component Information > Locations Diagnostic Connector: Locations An A-to-Z electrical components location list can be viewed at Vehicle/Locations. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Diagnostic Connector, Suspension > Component Information > Locations > Page 8319 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Locations Suspension Control Module: Locations An A-to-Z electrical components location list can be viewed at Vehicle/Locations. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Locations > Page 8323 Suspension Control Module: Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Mode Switch > Component Information > Specifications Suspension Mode Switch: Specifications TORQUE SPECIFICATIONS Air Suspension Switch Bracket Bolt ............................................................................................................................... 10.2-13.8 Nm (91-123 inch lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Warning Indicator > Component Information > Description and Operation Suspension Warning Indicator: Description and Operation The CK SUSP indicator will be illuminated if the instrument cluster receives a ground signal from the air suspension control module. The air suspension indicator will prove out when the ignition switch is placed in the START position and then in the RUN position. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Warning Indicator > Component Information > Description and Operation > Page 8330 Suspension Warning Indicator: Testing and Inspection Refer to Instrument Panel/Testing and Inspection/Procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Specifications Suspension Spring ( Coil / Leaf ): Specifications TORQUE SPECIFICATIONS Spring U-Bolt Nuts ............................................................................................................................... ................................... 98-132 Nm (73-97 ft. lbs.) Spring To Shackle Bolt And Nut ............................................................................................................................................. 98-132 Nm (73-97 ft. lbs.) Shackle To Frame Bracket ....................................................................................................................................................... 98-132 Nm (73-97 ft. lbs.) Spring To Frame ........................................................................................ ........................................................................ 213-288 Nm (157-212 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Specifications > Page 8334 Suspension Spring ( Coil / Leaf ): Description and Operation REAR SPRING Semi-elliptic, leaf-type rear springs are used for the rear suspension. Supplemental air springs are available as part of the optional air suspension system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Specifications > Page 8335 Suspension Spring ( Coil / Leaf ): Service and Repair Spring Tools Removal 1. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and the wheel bearings. Loosen the rear wheel lug nuts. 1. Remove the rear wheel center caps. 2. With the weight of the vehicle on the wheels, loosen but do not remove the lug nuts. 2. On vehicles equipped with rear air suspension, deflate the air springs. 3. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations. Raise and support the vehicle. 4. Remove the wheel and tire assembly. 5. Use the hi-lift jack to support the rear axle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Specifications > Page 8336 6. Separate the air spring from the air spring perch. 7. On vehicles equipped with rear air suspension, disconnect the air suspension height sensor. 8. On vehicles equipped with rear air suspension, disconnect the axle end of the anti-wind bar and position it out of the way. 9. WARNING: Lower the rear axle only enough to gain access to the rear spring. On vehicles not equipped with air suspension, separate the rear spring from the rear axle. 1. Remove the nuts. 2. Remove the U-bolts. 3. Remove the rear spring plates. 4. Carefully lower the rear axle. 5. On 4x4 vehicles, remove the rear spring spacer. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Specifications > Page 8337 10. WARNING: Lower the rear axle only enough to gain access to the rear spring. On air suspension vehicles, separate the rear spring from the rear axle. 1. Remove the nuts. 2. Remove the U-bolts. 3. Remove the rear spring plates. 4. Carefully lower the rear axle. 5. On 4x4 vehicles, remove the rear spring spacer. 11. WARNING: Do not remove an air spring under any circumstances when there is pressure in the air spring. Do not remove any components supporting an air spring without either exhausting the air or providing support for the air spring to prevent vehicle damage or personal injury. Remove the rear spring. 1. Remove the bolt and nut. 2. Remove the bolt and nut. 3. Remove the rear spring. Installation 1. Install the rear spring. 1. Position the rear spring. 2. Install the nut and bolt. 3. Install the nut and bolt. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Specifications > Page 8338 2. On vehicles equipped with rear air suspension, reconnect the air spring to the rear axle. 1. Position the spring perch. 2. Connect the air spring. 3. On vehicles equipped with rear air suspension, connect the rear axle. 1. On 4x4 equipped vehicles, position the rear spring spacer. 2. Position the U-bolts. 3. Install the rear spring plate. 4. Install the nuts. 4. On vehicles not equipped with rear air suspension, connect the rear axle. 1. On 4x4 equipped vehicles, position the rear spring spacer. 2. Position the U-bolts. 3. Install the rear spring plate. 4. Install the nuts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Specifications > Page 8339 5. NOTE: When installing the anti-wind bar, be sure to align it with the proper spring plate holes. On vehicles equipped with rear air suspension, connect the axle end of the anti-wind bar. ^ On 4x4 vehicles, install the anti-wind bar at the top hole of the spring plate. ^ On 4x2 vehicles, install the anti-wind bar at the bottom hole of the spring plate. 6. On vehicles equipped with rear air suspension, connect the height sensor. 7. Remove the hi-lift jack. 8. NOTE: On vehicles equipped with rear air suspension, reactivate the system by turning on the air suspension switch. Install the wheel and tire assembly. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Specifications > Page 8340 Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications Suspension Strut / Shock Absorber: Specifications TORQUE SPECIFICATIONS Front Shock Absorber Lower Bolt ........................................................................................................................................... 77-103 Nm (57-75 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Page 8344 Suspension Strut / Shock Absorber: Description and Operation The shock absorbers provide the necessary suspension dampening control. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Specifications Suspension Travel Bumper: Specifications TORQUE SPECIFICATIONS Rear Axle Bumper ............................................................................................................................... ...................................... 21-29 Nm (15-21 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information > Specifications > Page 8348 Suspension Travel Bumper: Service and Repair REAR AXLE BUMPERS The rear axle bumpers are used to prevent metal-to-metal contact between the rear axle and the frame. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torque Rod > Component Information > Specifications Torque Rod: Specifications TORQUE SPECIFICATIONS Anti-Wind Bar To U-Bolt Bracket Nut And Bolt ........................................................................................................................................ 113-153 Nm (88-112 ft. lbs.) Frame Bracket Nut And Bolt ......................................................................................................................................... 113-153 Nm (88-112 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torque Rod > Component Information > Specifications > Page 8352 Torque Rod: Description and Operation ANTI-WINDUP BAR The anti-windup bar compensates for rotational torque placed on the rear axle during acceleration and braking by preventing the rear axle and rear spring from twisting (winding up). The anti-windup bar minimizes noise and vibration issues caused by excessive pinion-to-driveshaft angles during acceleration and braking. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications Torsion Bar: Specifications TORQUE SPECIFICATIONS Torsion Bar Crossmember Support Bolt .................................................................................................................................... 40-54 Nm (29-39 ft. lbs.) Torsion Bar Crossmember Support Nut ..................................................................................................................................... 53-72 Nm (39-52 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications > Page 8356 Torsion Bar: Service and Repair Removal 1. Remove the torsion bar cover plate. 1. Remove the retaining bolts. 2. Remove the torsion bar cover plate. 2. Make preliminary adjustment references. ^ Measure and record the length, where indicated. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications > Page 8357 3. Relieve the torsion bar tension. 1. Position the torsion bar tool and the adapters. 2. Tighten the torsion bar tool until the torsion bar adjuster lifts off of the adjustment bolt. 4. CAUTION: The torsion bar adjustment bolt is coated with dry Loctite(R) and must be replaced if it is backed off or removed. Failure to do so can cause the adjustment bolt to loosen up during operation and a loss of vehicle alignment. Remove the torsion bar adjustment bolt and nut. 5. Loosen the torsion bar adjustment tool until the tension is off the torsion bar. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications > Page 8358 6. On F-150 Regular Cab (RC) Short Wheel Base (SWB), remove the torsion bar crossmember support and torsion bars. 1. Remove the eight bolts. 2. Remove the torsion bar crossmember support. 3. Remove the torsion bars. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications > Page 8359 1. On F-150 (RC) (SWB), install the torsion bar crossmember support and torsion bars. 2. CAUTION: The torsion bar adjustment bolt is coated with dry Loctite and must be replaced if it is backed off or removed. Failure to do so can cause the adjustment bolt to loosen up during operation and a loss of vehicle alignment. Preload the torsion bar. 1. Tighten the torsion bar tool until the new adjustment bolt and nut can be installed. 2. Turn the adjustment bolt until the preliminary adjustment measurement is reached (the recorded length of the old adjustment bolt). 3. Remove the torsion bar tool and adapters. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications > Page 8360 4. Install the torsion bar cover plate. 1. Position the torsion bar cover plate. 2. Install the retaining bolts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications > Page 8361 Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8366 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8367 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8368 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8369 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8370 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8371 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8372 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8373 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8374 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8375 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8376 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8377 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8378 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8379 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8380 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8381 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8382 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8383 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8384 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8385 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8386 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8387 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8388 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8389 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8390 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8391 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8392 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8393 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8394 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8395 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8396 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8397 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8398 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8399 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8400 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8401 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8402 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8403 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8404 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8405 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive 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Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8410 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8411 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8412 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8413 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8414 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8415 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8416 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8417 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8418 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8419 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8420 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8421 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8422 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8423 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8424 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8425 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8426 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8427 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8428 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8429 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8430 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8431 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8432 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8433 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8434 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8435 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8436 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8437 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8438 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8439 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8440 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8441 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8442 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8443 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8444 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8445 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8446 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8447 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8448 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8449 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8450 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8451 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8452 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8453 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8454 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8455 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8456 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8457 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8458 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8459 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8460 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Mechanical Specifications Wheel Bearing: Mechanical Specifications Maximum Axle Shaft End Play 0.762 mm Maximum Axle Shaft End Play 0.762 mm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Mechanical Specifications > Page 8463 Wheel Bearing: Fluid Type Specifications 8.8 Inch Ring Gear - Lubricate the new rear wheel bearing. Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. - Lubricate the lip of the new inner wheel bearing oil seal. Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 9.75 Inch Ring Gear - Lubricate the new rear wheel bearing. Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. - Lubricate the lip of the new inner wheel bearing oil seal. Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 8464 Wheel Bearing: Service Precautions CAUTION: Use only a grease that is recommended for wheel bearing applications. Use of the improper grease can cause bearing damage. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > 8.8-Inch Ring Gear Wheel Bearing: Service and Repair 8.8-Inch Ring Gear Special Tools Special Tools Removal 1. Remove the axle shaft. 2. NOTE: If the inner wheel bearing oil seal is leaking, the rear axle housing vent may be plugged. Using the special tools, remove the rear axle bearing and inner wheel bearing oil seal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > 8.8-Inch Ring Gear > Page 8467 Installation 1. Lubricate the new rear wheel bearing. - Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 2. Use the special tools to install the rear wheel bearing. 3. Lubricate the lip of the new inner wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tools, install the inner wheel bearing oil seal. 5. Install the axle shaft. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > 8.8-Inch Ring Gear > Page 8468 Wheel Bearing: Service and Repair 9.75-Inch Ring Gear Special Tools Special Tools Removal 1. Remove the axle shaft. 2. NOTE: If the inner wheel bearing oil seal is leaking, the rear axle housing vent may be plugged. Using the special tools, remove the rear wheel bearing and inner wheel bearing oil seal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > 8.8-Inch Ring Gear > Page 8469 Installation 1. Lubricate the new rear wheel bearing. - Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new inner wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tools, install the inner wheel bearing oil seal. 5. Install the axle shafts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Page 8470 Wheel Bearing: Tools and Equipment Special Tools Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications TORQUE SPECIFICATIONS Front Axle Hub Nut ........................................................................................................................................................... 255-345 Nm (188-254 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation Vehicle Lifting: Description and Operation Vehicle Lifting and Jacking JACKING WARNING - THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT DOWN PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. - DO NOT RUN THE ENGINE WHEN JACKING THE VEHICLE. THE WHEELS CONTACTING THE GROUND COULD CAUSE THE VEHICLE TO MOVE. - SUPPORT THE VEHICLE PRIOR TO PERFORMING ANY PROCEDURE REQUIRING THE VEHICLE TO BE JACKED OFF THE GROUND. - MAKE SURE THE JACK AND JACK STANDS ARE PROPERLY LOCATED TO PREVENT THE VEHICLE FROM FALLING. - WHEEL CHOCKS SHOULD BE USED TO PREVENT THE VEHICLE FROM ROLLING AND FALLING OFF THE JACK. CAUTION: Never use a halfshaft as a lifting point. Jacking Points - Front, 4x4 The jacking point is a raised boss located on the front suspension lower arm. Jacking Points - Front, 4x2 The jacking point is a flat portion on the frame indicated by the arrow cut out. The jacking point is located behind the front tire and wheel assembly. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 8479 Jacking Points - Rear CAUTION: Never use the differential housing as a lifting point. The rear jacking points are located on the rear axle. LIFTING WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRING WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE PROCEDURES. CAUTION: Damage to suspension, exhaust and steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle Lifting Points - Twin Post Hoist Locate the front hoist adapters and rear hoist adapters (top of frame arc) as indicated. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 8480 Vehicle Lifting: Service and Repair Vehicle Lifting and Jacking JACKING WARNING - THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT DOWN PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS. - DO NOT RUN THE ENGINE WHEN JACKING THE VEHICLE. THE WHEELS CONTACTING THE GROUND COULD CAUSE THE VEHICLE TO MOVE. - SUPPORT THE VEHICLE PRIOR TO PERFORMING ANY PROCEDURE REQUIRING THE VEHICLE TO BE JACKED OFF THE GROUND. - MAKE SURE THE JACK AND JACK STANDS ARE PROPERLY LOCATED TO PREVENT THE VEHICLE FROM FALLING. - WHEEL CHOCKS SHOULD BE USED TO PREVENT THE VEHICLE FROM ROLLING AND FALLING OFF THE JACK. CAUTION: Never use a halfshaft as a lifting point. Jacking Points - Front, 4x4 The jacking point is a raised boss located on the front suspension lower arm. Jacking Points - Front, 4x2 The jacking point is a flat portion on the frame indicated by the arrow cut out. The jacking point is located behind the front tire and wheel assembly. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information > Description and Operation > Page 8481 Jacking Points - Rear CAUTION: Never use the differential housing as a lifting point. The rear jacking points are located on the rear axle. LIFTING WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRING WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE PROCEDURES. CAUTION: Damage to suspension, exhaust and steering linkage components may occur if care is not exercised when positioning the hoist adapters prior to lifting the vehicle Lifting Points - Twin Post Hoist Locate the front hoist adapters and rear hoist adapters (top of frame arc) as indicated. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01L07 > Dec > 01 > Recall - Supplementary Tire Label Installation Technical Service Bulletin # 01L07 Date: 011201 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01L07 > Dec > 01 > Recall - Supplementary Tire Label Installation > Page 8490 Attachment I - Administrative Information OASIS OASIS will not be activated for this program. PLEASE NOTE Correct all vehicles in stock before delivery. DEALER-OWNER CONTACT An owner list will not be provided. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Parts and Labor Information LABOR ALLOWANCES PARTS REQUIREMENTS Ordering Instructions for Additional Labels Supplemental Tire Information Labels for this program are being sent directly to owners of the affected vehicles. Additional labels may be ordered at no charge by calling the Special Service Support Center at 1-800-325-5621. Inform the operator you are calling in regard to Field Service Action 01L07. Be prepared to provide your name, address, dealer P & A code, and the number of labels you need. Attachment III - Technical Information SUPPLEMENTAL TIRE INFORMATION LABEL AFFECTED VEHICLES: CERTAIN 1999 MODEL YEAR F-150 4X4 MODELS EQUIPPED WITH HEAVY-DUTY SERVICE PACKAGE SERVICE PROCEDURE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01L07 > Dec > 01 > Recall - Supplementary Tire Label Installation > Page 8491 ^ Open the driver's door. ^ Locate the original vehicle certification label on the B-pillar below the latch striker. ^ Check the tire size and the tire air pressure specifications on the label. Tire size should be listed as P255/70R6SL. Front and rear tire air pressure should be listed as 32 PSI/220 kPa. Label On Your Vehicle Is Correct: If tire size and air pressures are listed correctly on the label, you do not need to do anything. You may discard the enclosed supplemental label. Label On Your Vehicle Is NOT Correct: If tire size and air pressures are not listed correctly, please attach the supplemental label as follows: 1. Clean the area below the vehicle certification label using isopropyl alcohol (commonly referred to as rubbing alcohol) and a clean rag. 2. Remove any non-permanent labels such as oil change labels, if necessary. If there are any other permanent labels in this location, clean an area large enough to allow for full adhesion. 3. Allow the area to dry completely. 4. Peel the backing off the new supplemental tire information label and install it as shown. See Figure 1. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01L07 > Dec > 01 > Recall - Supplementary Tire Label Installation > Page 8492 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 01L07 > Dec > 01 > Recall - Supplementary Tire Label Installation > Page 8493 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > NHTSA99V039000 > Feb > 00 > Recall 99V039000: Tire and Rim Identification Label Tires: Recalls Recall 99V039000: Tire and Rim Identification Label Vehicle Description: 4x4 vehicles with Off Road and High FGAWR option packages, and 4x2 vehicles with Sport option package. The tire and rim identification information is incorrect on the certification labels for these vehicles. This does not meet the requirements of FMVSS No. 120, "Tire Selection and Rims for Motor Vehicles other than Passenger Cars. "If incorrect tire information is given, underrated tires could be placed on the truck causing excessive tire wear or, in extreme cases, possible tire blowouts. Owners will be provided with a revised label overlay. Owner notification began June 9, 1999. Owners who do not receive the free revised label within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1999 FORD TRUCK F150 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label Technical Service Bulletin # 99S03 Date: 990601 Recall - Wheels/Tires, Incorrect Certification Label 99S03 SAFETY RECALL Certain 1999 Model Year F-150 Trucks Safety Compliance Certification Label - Wheel and Tire Size Designation ^ Dealer Letter ^ Attachment I ^ Attachment II ^ Labor Allowances ^ Parts Ordering information ^ Attachment III ^ Technical Information ^ Customer Notification Letter Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label > Page 8502 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label > Page 8503 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct the affected vehicles returned to your dealership, on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator (FDCC). Other eligible vehicles which are brought to your dealership. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS SUBMISSION Enter claims using DWE. See ACESII Manual, Sections 5 and 6. Attachment II - Labor and Parts Information Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label > Page 8504 LABOR ALLOWANCES PARTS REQUIREMENTS Safety Certification Partial Overlay Labels and installation instructions will be mailed to the vehicle owners. In addition, the owners will be notified that if they prefer, they may have the dealership personnel install the label at no charge. Labels and instructions for vehicles not reported as sold will be included in the Ford Dealership Consolidated Communicator (FDCC). If the customer no longer has the label, call the Recall Hotline (1-800-325-5621). When calling this number to order labels and instructions, be prepared to give the recall number 99S03. Attachment III - Technical Information IMPORTANT NOTICE TO OWNERS OF TWO (2) OR MORE F-150 TRUCKS The Safety Certification Label is matched to the Vehicle Identification Number (VIN) for each letter. To make sure that the correct label is attached to the correct vehicle, do not separate the Safety Certification Labels from the letters until you are ready to attach the label to the truck. INSTRUCTIONS FOR ATTACHING THE LABEL 1. Open the driver's door and locate the "Safety Certification Label", on the "B" pillar at the door opening. See Figure 1. 2. Verify that the VIN on the letter is the same as the VIN on the vehicle. NOTE: The vehicle VIN is located in two places: a) behind the left lower corner of the windshield and b) on the driver's door "B" pillar Safety Certification Label. 3. Clean the label and surrounding area with the supplied Label Adhesive Cleaning Pad. 4. Remove the partial label from the letter and place it over the cleaned area so the partial label is directly over the upper portion of the label as illustrated by the unshaded area of Figure 1. Use care not to cover the other information on the existing label. Smooth out air bubbles with a clean cloth. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label > Page 8505 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Recalls: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label > Page 8506 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page 8512 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01L07 > Dec > 01 > Recall - Supplementary Tire Label Installation Technical Service Bulletin # 01L07 Date: 011201 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01L07 > Dec > 01 > Recall - Supplementary Tire Label Installation > Page 8517 Attachment I - Administrative Information OASIS OASIS will not be activated for this program. PLEASE NOTE Correct all vehicles in stock before delivery. DEALER-OWNER CONTACT An owner list will not be provided. CLAIMS PREPARATION AND SUBMISSION ^ Enter claims using DWE. ^ Refer to ACESII manual for claims preparation and submission information. Attachment II - Parts and Labor Information LABOR ALLOWANCES PARTS REQUIREMENTS Ordering Instructions for Additional Labels Supplemental Tire Information Labels for this program are being sent directly to owners of the affected vehicles. Additional labels may be ordered at no charge by calling the Special Service Support Center at 1-800-325-5621. Inform the operator you are calling in regard to Field Service Action 01L07. Be prepared to provide your name, address, dealer P & A code, and the number of labels you need. Attachment III - Technical Information SUPPLEMENTAL TIRE INFORMATION LABEL AFFECTED VEHICLES: CERTAIN 1999 MODEL YEAR F-150 4X4 MODELS EQUIPPED WITH HEAVY-DUTY SERVICE PACKAGE SERVICE PROCEDURE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01L07 > Dec > 01 > Recall - Supplementary Tire Label Installation > Page 8518 ^ Open the driver's door. ^ Locate the original vehicle certification label on the B-pillar below the latch striker. ^ Check the tire size and the tire air pressure specifications on the label. Tire size should be listed as P255/70R6SL. Front and rear tire air pressure should be listed as 32 PSI/220 kPa. Label On Your Vehicle Is Correct: If tire size and air pressures are listed correctly on the label, you do not need to do anything. You may discard the enclosed supplemental label. Label On Your Vehicle Is NOT Correct: If tire size and air pressures are not listed correctly, please attach the supplemental label as follows: 1. Clean the area below the vehicle certification label using isopropyl alcohol (commonly referred to as rubbing alcohol) and a clean rag. 2. Remove any non-permanent labels such as oil change labels, if necessary. If there are any other permanent labels in this location, clean an area large enough to allow for full adhesion. 3. Allow the area to dry completely. 4. Peel the backing off the new supplemental tire information label and install it as shown. See Figure 1. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01L07 > Dec > 01 > Recall - Supplementary Tire Label Installation > Page 8519 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 01L07 > Dec > 01 > Recall - Supplementary Tire Label Installation > Page 8520 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > NHTSA99V039000 > Feb > 00 > Recall 99V039000: Tire and Rim Identification Label Tires: All Technical Service Bulletins Recall 99V039000: Tire and Rim Identification Label Vehicle Description: 4x4 vehicles with Off Road and High FGAWR option packages, and 4x2 vehicles with Sport option package. The tire and rim identification information is incorrect on the certification labels for these vehicles. This does not meet the requirements of FMVSS No. 120, "Tire Selection and Rims for Motor Vehicles other than Passenger Cars. "If incorrect tire information is given, underrated tires could be placed on the truck causing excessive tire wear or, in extreme cases, possible tire blowouts. Owners will be provided with a revised label overlay. Owner notification began June 9, 1999. Owners who do not receive the free revised label within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1999 FORD TRUCK F150 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8529 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8530 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8531 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8532 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8533 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8534 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8535 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8536 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8537 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8538 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8539 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8540 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8541 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8542 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8543 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8544 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8545 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8546 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8547 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8548 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8549 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8550 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8551 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8552 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8553 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8554 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8555 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8556 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8557 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8558 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8559 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8560 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8561 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8562 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8563 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8564 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8565 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8566 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8567 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8568 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8569 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8570 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8571 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8572 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8573 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8574 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8575 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8576 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8577 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8578 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8579 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8580 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8581 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8582 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8583 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8584 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8585 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8586 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8587 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8588 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8589 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8590 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8591 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8592 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8593 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8594 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8595 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8596 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8597 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8598 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8599 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8600 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8601 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8602 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8603 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8604 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8605 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8606 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8607 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8608 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8609 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8610 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8611 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8612 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8613 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8614 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8615 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8616 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8617 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8618 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8619 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8620 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8621 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8622 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8623 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label Technical Service Bulletin # 99S03 Date: 990601 Recall - Wheels/Tires, Incorrect Certification Label 99S03 SAFETY RECALL Certain 1999 Model Year F-150 Trucks Safety Compliance Certification Label - Wheel and Tire Size Designation ^ Dealer Letter ^ Attachment I ^ Attachment II ^ Labor Allowances ^ Parts Ordering information ^ Attachment III ^ Technical Information ^ Customer Notification Letter Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label > Page 8628 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label > Page 8629 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct the affected vehicles returned to your dealership, on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator (FDCC). Other eligible vehicles which are brought to your dealership. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS SUBMISSION Enter claims using DWE. See ACESII Manual, Sections 5 and 6. Attachment II - Labor and Parts Information Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label > Page 8630 LABOR ALLOWANCES PARTS REQUIREMENTS Safety Certification Partial Overlay Labels and installation instructions will be mailed to the vehicle owners. In addition, the owners will be notified that if they prefer, they may have the dealership personnel install the label at no charge. Labels and instructions for vehicles not reported as sold will be included in the Ford Dealership Consolidated Communicator (FDCC). If the customer no longer has the label, call the Recall Hotline (1-800-325-5621). When calling this number to order labels and instructions, be prepared to give the recall number 99S03. Attachment III - Technical Information IMPORTANT NOTICE TO OWNERS OF TWO (2) OR MORE F-150 TRUCKS The Safety Certification Label is matched to the Vehicle Identification Number (VIN) for each letter. To make sure that the correct label is attached to the correct vehicle, do not separate the Safety Certification Labels from the letters until you are ready to attach the label to the truck. INSTRUCTIONS FOR ATTACHING THE LABEL 1. Open the driver's door and locate the "Safety Certification Label", on the "B" pillar at the door opening. See Figure 1. 2. Verify that the VIN on the letter is the same as the VIN on the vehicle. NOTE: The vehicle VIN is located in two places: a) behind the left lower corner of the windshield and b) on the driver's door "B" pillar Safety Certification Label. 3. Clean the label and surrounding area with the supplied Label Adhesive Cleaning Pad. 4. Remove the partial label from the letter and place it over the cleaned area so the partial label is directly over the upper portion of the label as illustrated by the unshaded area of Figure 1. Use care not to cover the other information on the existing label. Smooth out air bubbles with a clean cloth. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label > Page 8631 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label > Page 8632 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page 8638 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8643 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8644 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8645 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8646 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8647 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8648 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8649 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8650 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8651 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8652 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8653 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8654 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8655 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8656 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8657 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8658 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8659 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8660 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8661 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8662 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8663 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8664 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8665 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8666 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8667 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8668 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8669 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8670 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8671 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8672 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8673 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8674 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8675 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8676 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8677 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8678 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8679 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8680 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8681 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8682 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8683 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8684 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8685 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8686 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8687 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8688 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8689 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8690 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8691 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8692 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8693 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8694 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8695 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8696 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8697 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8698 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8699 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8700 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8701 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8702 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8703 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8704 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8705 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8706 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8707 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8708 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8709 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8710 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8711 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8712 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8713 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8714 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8715 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8716 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8717 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8718 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8719 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8720 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8721 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8722 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8723 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8724 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8725 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8726 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8727 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8728 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8729 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8730 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8731 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8732 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8733 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8734 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8735 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8736 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8737 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Specifications > Mechanical Specifications Tires: Mechanical Specifications OPERATIONAL SPECIFICATIONS Tire Tread Depth LT245/75R16 A/S ................................................................................................................................ ....................................... 11.5 mm (0.45 inch) LT245/75R16 A/T ....................................................... ................................................................................................................ 12.9 mm (0.51 inch) P235/70R16 A/S .................................................................................................................................. ......................................... 9.1 mm (0.36 inch) P235/70R16 A/T ......................................................... ................................................................................................................. 10.4 mm (0.41 inch) P255/70R16 A/S .................................................................................................................................. .......................................... 9.4 mm (0.37 inch) P255/70R16 A/T ........................................................ .................................................................................................................. 10.7 mm (0.42 inch) P265/70R17 A/T .................................................................................................................................. ........................................ 10.9 mm (0.43 inch) P275/60R17 A/S ........................................................ .................................................................................................................... 9.1 mm (0.36 inch) Tire Runout .......................................................................................................................................... .............................................. 1.27 mm (0.05 inch) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Specifications > Mechanical Specifications > Page 8740 Tires: Pressure, Vacuum and Temperature Specifications Tire Inflation ................................................................................................................................... See Safety Certification Label On Driver Door Jamb Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Specifications > Page 8741 Tires: Service and Repair Removal 1. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and wheel bearings. NOTE: To avoid damage or scratching to the center cap, place facing up when removed. Loosen the lug nuts. 1. Remove the center cap. 2. With the weight of the vehicle on the wheels, loosen the lug nuts. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 3. Raise and support the vehicle. 4. Remove the wheel and tire assembly. 1. Remove the lug nuts. 2. Remove the wheel and tire assembly, using a side-to-side rocking motion. Installation 1. WARNING: When a wheel is installed, always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the lug nuts to loosen and the wheel to come off while the vehicle is in motion, causing loss of control. Clean the wheel hub mounting surface and wheel centering O-ring. 2. Install the tire and wheel assembly. 1. Inspect the wheel centering O-ring. Replace if damaged. 2. Position the tire and wheel assembly. 3. Install the lug nuts hand-tight, then lower the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Specifications > Page 8742 3. CAUTION: Failure to tighten the lug nuts in a star pattern can result in high brake disc runout, which will speed up the development of brake roughness, shudder and vibration. Tighten the lug nuts in sequence. 4. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Install the center cap. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Recalls: > NHTSA99V039000 > Feb > 00 > Recall 99V039000: Tire and Rim Identification Label Wheels: Recalls Recall 99V039000: Tire and Rim Identification Label Vehicle Description: 4x4 vehicles with Off Road and High FGAWR option packages, and 4x2 vehicles with Sport option package. The tire and rim identification information is incorrect on the certification labels for these vehicles. This does not meet the requirements of FMVSS No. 120, "Tire Selection and Rims for Motor Vehicles other than Passenger Cars. "If incorrect tire information is given, underrated tires could be placed on the truck causing excessive tire wear or, in extreme cases, possible tire blowouts. Owners will be provided with a revised label overlay. Owner notification began June 9, 1999. Owners who do not receive the free revised label within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1999 FORD TRUCK F150 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Recalls: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label Technical Service Bulletin # 99S03 Date: 990601 Recall - Wheels/Tires, Incorrect Certification Label 99S03 SAFETY RECALL Certain 1999 Model Year F-150 Trucks Safety Compliance Certification Label - Wheel and Tire Size Designation ^ Dealer Letter ^ Attachment I ^ Attachment II ^ Labor Allowances ^ Parts Ordering information ^ Attachment III ^ Technical Information ^ Customer Notification Letter Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Recalls: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label > Page 8755 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Recalls: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label > Page 8756 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct the affected vehicles returned to your dealership, on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator (FDCC). Other eligible vehicles which are brought to your dealership. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS SUBMISSION Enter claims using DWE. See ACESII Manual, Sections 5 and 6. Attachment II - Labor and Parts Information Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Recalls: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label > Page 8757 LABOR ALLOWANCES PARTS REQUIREMENTS Safety Certification Partial Overlay Labels and installation instructions will be mailed to the vehicle owners. In addition, the owners will be notified that if they prefer, they may have the dealership personnel install the label at no charge. Labels and instructions for vehicles not reported as sold will be included in the Ford Dealership Consolidated Communicator (FDCC). If the customer no longer has the label, call the Recall Hotline (1-800-325-5621). When calling this number to order labels and instructions, be prepared to give the recall number 99S03. Attachment III - Technical Information IMPORTANT NOTICE TO OWNERS OF TWO (2) OR MORE F-150 TRUCKS The Safety Certification Label is matched to the Vehicle Identification Number (VIN) for each letter. To make sure that the correct label is attached to the correct vehicle, do not separate the Safety Certification Labels from the letters until you are ready to attach the label to the truck. INSTRUCTIONS FOR ATTACHING THE LABEL 1. Open the driver's door and locate the "Safety Certification Label", on the "B" pillar at the door opening. See Figure 1. 2. Verify that the VIN on the letter is the same as the VIN on the vehicle. NOTE: The vehicle VIN is located in two places: a) behind the left lower corner of the windshield and b) on the driver's door "B" pillar Safety Certification Label. 3. Clean the label and surrounding area with the supplied Label Adhesive Cleaning Pad. 4. Remove the partial label from the letter and place it over the cleaned area so the partial label is directly over the upper portion of the label as illustrated by the unshaded area of Figure 1. Use care not to cover the other information on the existing label. Smooth out air bubbles with a clean cloth. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Recalls: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label > Page 8758 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Recalls: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label > Page 8759 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page 8765 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > NHTSA99V039000 > Feb > 00 > Recall 99V039000: Tire and Rim Identification Label Wheels: All Technical Service Bulletins Recall 99V039000: Tire and Rim Identification Label Vehicle Description: 4x4 vehicles with Off Road and High FGAWR option packages, and 4x2 vehicles with Sport option package. The tire and rim identification information is incorrect on the certification labels for these vehicles. This does not meet the requirements of FMVSS No. 120, "Tire Selection and Rims for Motor Vehicles other than Passenger Cars. "If incorrect tire information is given, underrated tires could be placed on the truck causing excessive tire wear or, in extreme cases, possible tire blowouts. Owners will be provided with a revised label overlay. Owner notification began June 9, 1999. Owners who do not receive the free revised label within a reasonable time should contact Ford at 1-800-392-3673. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236). 1999 FORD TRUCK F150 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8774 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8775 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8776 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8777 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8778 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8779 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8780 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8781 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8782 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8783 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8784 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8785 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8786 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8787 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8788 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8789 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8790 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8791 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8792 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8793 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8794 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8795 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8796 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8797 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8798 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8799 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8800 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8801 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8802 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8803 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8804 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8805 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8806 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8807 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8808 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8809 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8810 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8811 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8812 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8813 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8814 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8815 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8816 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8817 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8818 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8819 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8820 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8821 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8822 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8823 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8824 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8825 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8826 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8827 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8828 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8829 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8830 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8831 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8832 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8833 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8834 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8835 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8836 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8837 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8838 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8839 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8840 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8841 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8842 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8843 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8844 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8845 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8846 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8847 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8848 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8849 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8850 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8851 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8852 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8853 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8854 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8855 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8856 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8857 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8858 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8859 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8860 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8861 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8862 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8863 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8864 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8865 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8866 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8867 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-11-1 > Jun > 99 > Comprehensive Noise/Vibration/Harshness Procedure > Page 8868 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label Technical Service Bulletin # 99S03 Date: 990601 Recall - Wheels/Tires, Incorrect Certification Label 99S03 SAFETY RECALL Certain 1999 Model Year F-150 Trucks Safety Compliance Certification Label - Wheel and Tire Size Designation ^ Dealer Letter ^ Attachment I ^ Attachment II ^ Labor Allowances ^ Parts Ordering information ^ Attachment III ^ Technical Information ^ Customer Notification Letter Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label > Page 8873 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label > Page 8874 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT Promptly correct the affected vehicles returned to your dealership, on the "Involved Units Listing" in the Ford Dealership Consolidated Communicator (FDCC). Other eligible vehicles which are brought to your dealership. REGIONAL CONTACT Advise regional office if an owner: ^ cannot be contacted. ^ does not make a service date. CLAIMS SUBMISSION Enter claims using DWE. See ACESII Manual, Sections 5 and 6. Attachment II - Labor and Parts Information Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label > Page 8875 LABOR ALLOWANCES PARTS REQUIREMENTS Safety Certification Partial Overlay Labels and installation instructions will be mailed to the vehicle owners. In addition, the owners will be notified that if they prefer, they may have the dealership personnel install the label at no charge. Labels and instructions for vehicles not reported as sold will be included in the Ford Dealership Consolidated Communicator (FDCC). If the customer no longer has the label, call the Recall Hotline (1-800-325-5621). When calling this number to order labels and instructions, be prepared to give the recall number 99S03. Attachment III - Technical Information IMPORTANT NOTICE TO OWNERS OF TWO (2) OR MORE F-150 TRUCKS The Safety Certification Label is matched to the Vehicle Identification Number (VIN) for each letter. To make sure that the correct label is attached to the correct vehicle, do not separate the Safety Certification Labels from the letters until you are ready to attach the label to the truck. INSTRUCTIONS FOR ATTACHING THE LABEL 1. Open the driver's door and locate the "Safety Certification Label", on the "B" pillar at the door opening. See Figure 1. 2. Verify that the VIN on the letter is the same as the VIN on the vehicle. NOTE: The vehicle VIN is located in two places: a) behind the left lower corner of the windshield and b) on the driver's door "B" pillar Safety Certification Label. 3. Clean the label and surrounding area with the supplied Label Adhesive Cleaning Pad. 4. Remove the partial label from the letter and place it over the cleaned area so the partial label is directly over the upper portion of the label as illustrated by the unshaded area of Figure 1. Use care not to cover the other information on the existing label. Smooth out air bubbles with a clean cloth. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label > Page 8876 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99S03 > Jun > 99 > Recall - Wheels/Tires, Incorrect Certification Label > Page 8877 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts Technical Service Bulletin # 02-1-6 Date: 020121 Wheels/Tires - Road Force Measurement Equipment Article No. 02-1-6 01/21/02 ^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS ^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE 1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center verification and warranty restrictions. This type of equipment can be a valuable tool to improve customer satisfaction when used as a vibration repair tool. This type of equipment can also provide a high level of customer satisfaction when used as an assembly too! when the customer has purchased new wheels/tires in the "Around-the-Wheel" program. ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will minimize the contribution to vibration from the tire/wheel assembly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 703000 Service Information NOTE TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION" ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS. NOTE WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON HUNTER G5P9700 RESULTS. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 8883 NOTE UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R" KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES. 1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers recommended pressure. The vehicle manufacturers recommended tire pressure for the original equipment tires can be found on the drivers side door placard. 2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test at highway speeds is preferred. NOTE THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES). 3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack stands to prevent measurement errors due to further flat spotting. 4. Assembly centering verification MUST be performed and PASSED prior to any road force measurement. For those with a software version other than 2.1 the centering verification must be performed manually. a. Spin assembly to measure. Record the assembly R1H. b. Loosen wing-nut. c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees). d. Tighten wing-nut. e. Re-spin to measure. Record the assembly R1H. f. Compare results obtained in STEP a with those obtained in STEP e. g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering verification PASSES and technician can proceed to the measurement/repair process. If the centering verification FAILS proceed to STEP h. h. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 5. For those with software version 2.1 the following procedure will lead the technician through a Centering Check. a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows). b. Push the "K1" button to select Perform Centering Check. c. Follow the instructions. d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check fails proceed to step e. e. The following items may contribute to an assembly centering verification FAILURE. ^ Cone/adapter does not fit properly or is incorrect for the application ^ The wheel mounting surface is damaged 6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic balancing mode. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 8884 Wheels: Specifications OPERATIONAL SPECIFICATIONS O-Ring .......................................................................................................................................................... 82 mm Diameter x 2.34 mm Square Section Wheel Stud And Lug Nuts .......................................................................................................................................................... M12 x 1.75 - 19 mm hex Max. Balance Weight (Total Of Inner & Outer Wheel Flanges) ......................................................................................................................... ...................................................... 170 g (6 oz) Cast Aluminum .................................................................................................................................... .................................................................. 17x7.5J Steel .................................................................... ...................................................................................................................................................... 16x7J Styled Aluminum ....................................................................................................................... ............................................................................... 16x7J Styled Argent Steel ................................... .............................................................................................................................................................. .. 16x7J Styled Chrome Steel .............................................................................................................. ................................................................................... 16x7J Wrought Aluminum ............................... .............................................................................................................................................................. ..... 16x7J Wheel Offset ....................................................................................................................... .................................................................................... 14 mm Wheel Rim Runout (Radial Or Lateral) ........................................................................................................................................... 1.12 mm (0.044 inch) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Leaks Wheels: Service and Repair Leaks 1. Forged aluminum wheels do not get pinhole leaks and should not be repaired using Aluminum Wheel Repair Compound. 2. Pinhole leaks in cast aluminum wheels compromise wheel integrity. Replace the wheel. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Leaks > Page 8887 Wheels: Service and Repair Replacement Removal 1. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and wheel bearings. NOTE: To avoid damage or scratching to the center cap, place facing up when removed. Loosen the lug nuts. 1. Remove the center cap. 2. With the weight of the vehicle on the wheels, loosen the lug nuts. 2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 3. Raise and support the vehicle. 4. Remove the wheel and tire assembly. 1. Remove the lug nuts. 2. Remove the wheel and tire assembly, using a side-to-side rocking motion. Installation 1. WARNING: When a wheel is installed, always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the lug nuts to loosen and the wheel to come off while the vehicle is in motion, causing loss of control. Clean the wheel hub mounting surface and wheel centering O-ring. 2. Install the tire and wheel assembly. 1. Inspect the wheel centering O-ring. Replace if damaged. 2. Position the tire and wheel assembly. 3. Install the lug nuts hand-tight, then lower the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Leaks > Page 8888 3. CAUTION: Failure to tighten the lug nuts in a star pattern can result in high brake disc runout, which will speed up the development of brake roughness, shudder and vibration. Tighten the lug nuts in sequence. 4. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch. Install the center cap. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure Technical Service Bulletin # 99-11-1 Date: 990614 Comprehensive Noise/Vibration/Harshness Procedure Article No. 99-11-1 06/14/99 ^ NOISE - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS ^ VIBRATION - TSB SPECIAL FOR NOISE/VIBRATION/HARSHNESS FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-1997 COUGAR 1995-1998 MARK VIII 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR 2000 LS LIGHT TRUCK: 1995-1997 F SUPER DUTY, F-250 HD, F-350 1995-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE This TSB article is being published as a comprehensive Noise, Vibration and Harshness (NVH) diagnostic procedure. This procedure will also be in 2000 model year and future Workshop Manuals in the NVH Section. ACTION Utilize the flowchart diagrams to work a problem from SYMPTOM to SYSTEM to COMPONENT to CAUSE. The tools and techniques section is expanded to include ALL NVH diagnostic "tools". There are expanded SYMPTOM CHARTS to assist with problem resolution. A revised NVH course is available through regional training centers. The course is "NVH Principals and Diagnostics", course code # 30s03t0. This course utilizes the same techniques that are in the revised diagnostic procedure. Refer to the Noise, Vibration and Harshness Work Shop Manual Section that is included. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 497000, 597997, 701000, 702000, 703000 SECTION 100-04 Noise, Vibration and Harshness VEHICLE APPLICATION: Noise, Vibration and Harshness CONTENTS DESCRIPTION AND OPERATION Noise, Vibration and Harshness (NVH) Acceptable Noise, Vibration and Harshness Diagnostic Theory Diagnostic Process Glossary of Terms Tools and Techniques DIAGNOSIS AND TESTING Noise, Vibration and Harshness (NVH) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8893 Component Tests Diagnostic Process 1: Customer Interview 2: Pre-Drive Check 3: Preparing for the Road Test 4: Verify the Customer Concern 5: Road Test 6: Check OASIS/TSBs/Repair History 7: Diagnostic Procedure NVH Condition and Symptom Categories Pinpoint Tests Symptom Charts GENERAL PROCEDURES Exhaust System Neutralizing Powertrain/Drivetrain Mount Neutralizing Wheel Bearing Check Noise, Vibration and Harshness (NVH) Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally describes a firmer than usual response from the suspension system. Noise, vibration and harshness (NVH) is a term used to describe these conditions, which customers sense and result in varying degrees of dissatisfaction. Although, a certain level of NVH caused by road and environmental conditions is normal. This section is designed to aid in the diagnosis, testing and repair of NVH concerns. Acceptable Noise, Vibration and Harshness All internal combustion engines and drivelines produce some noise and vibration; operating in a real world environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal when actually the sounds are normal for the vehicle type. For example, Traction-Lok(R) differentials produce a slight noise on slow turns after extended highway driving. This is acceptable and has no detrimental effect on the locking axle function. As a technician, it is very important to be familiar with vehicle features and know how they relate to NVH concerns and their diagnosis. If, for example, the vehicle has automatic overdrive it is important to test drive the vehicle both in and out of overdrive mode. Diagnostic Theory The shortest route to an accurate diagnosis results from: ^ system knowledge, including comparison with a known good system. ^ system history, including repair history and usage patterns. ^ condition history, especially any relationship to repairs or sudden change. ^ knowledge of probable causes ^ using a systematic diagnostic method that divides the system into related areas. The diagnosis and correction of noise, vibration and harshness concerns requires: ^ a road or system test to determine the exact nature of the concern. ^ an analysis of the possible causes. ^ testing to verify the cause. ^ repairing any concerns found. ^ a road test or system test to make sure the concern has been corrected or brought back to within a acceptable range. Diagnostic Process A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system. The following flowcharts are a graphic representation of the diagnostic process. Use the flowcharts as follows: ^ Choose the appropriate flowchart. ^ Identify the operating condition that the vehicle is exhibiting. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8894 ^ Advance through the flowchart from left to right. ^ Match the operating condition to the symptom. ^ Verify the symptom. ^ Identify which category or system could cause the symptom. ^ Refer to the diagnostic symptom chart that the flowchart refers to. Glossary of Terms Acceleration-Light An increase in speed at less than half throttle. Acceleration-Medium An increase in speed at half to nearly full throttle, such as 0-97 km/h (0-60 mph) in approximately 30 seconds. Acceleration-Heavy An increase in speed at one-half to full throttle, such as 0-97 km/h (0-60 mph) in approximately 20 seconds. Ambient Temperature The surrounding or prevailing temperature. Amplitude The quantity or amount of energy produced by a vibrating component (G force). An extreme vibration has a high amplitude. A mild vibration has a low amplitude. Backlash Gear teeth clearance. Boom Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming. Bound Up An overstressed isolation (rubber) mount that transmits vibration/noise instead of absorbing it. Brakes Applied When the service brakes are applied with enough force to hold the vehicle against movement with the transmission in gear. Buffet/Buffeting Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass. Buzz A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a high frequency (200-800 Hz) vibration. Vibration feels similar to an electric razor. Camber The angle of the wheel in relation to the true vertical as measured looking from the front of the vehicle. Camber is positive when the wheel angle is offset so that the top of the wheel is positioned away from the vehicle. Caster The angle of the steering knuckle in relation to the true vertical as measured looking from the side of the vehicle. Chatter A pronounced series of rapidly repeating rattling or clicking sounds. Chirp A short-duration high-pitched noise associated with a slipping drive belt. Chuckle A repetitious low-pitched sound. A loud chuckle is usually described as a knock. Click A sharp, brief, non-resonant sound, similar to actuating a ball point pen. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8895 Clonk A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as hammering. Clunk/Driveline Clunk A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or decelerating abruptly. Also described as a thunk. Coast/Deceleration Releasing the accelerator pedal at cruise, allowing the engine to reduce vehicle speed without applying the brakes. Coast/Neutral Coast Placing the transmission range selector in NEUTRAL (N) or depressing the clutch pedal while at cruise. Constant Velocity (CV) Joint A joint used to absorb vibrations caused by driving power being transmitted at an angle. Controlled Rear Suspension Height The height at which a designated vehicle element must be when driveline angle measurements are made. Coupling Shaft The shaft between the transfer case and the front drive axle or, in a two-piece rear driveshaft, the front section. CPS Cycles per second. Same as hertz (Hz). Cracks A mid-frequency sound, related to squeak. Sound varies with temperature conditions. Creak A metallic squeak. Cruise Constant speed on level ground; neither accelerating nor decelerating. Cycle The process of a vibrating component going through a complete range of motion and returning to the starting point. Decibel A unit of measurement, referring to sound pressure level, abbreviated dB. Drive Engine Run-Up (DERU) Test The operation of the engine through the normal rpm range with the vehicle standing still, the brakes applied and the transmission engaged. This test is used for noise and vibration checks. Driveline Angles The differences of alignment between the transmission output shaft, the drive shaft, and the rear axle pinion centerline. Driveshaft The shaft that transmits power to the rear axle input shaft (pinion shaft). In a two-piece driveshaft, it is the rearmost shaft. Drivetrain All power transmitting components from the engine to the wheels; includes the clutch or torque converter, the transmission, the transfer case, the driveshaft, and the front or rear drive axle. Drivetrain Damper A weight attached to the engine, the transmission, the transfer case, or the axle. It is tuned by weight and placement to absorb vibration. Drone A low frequency (100-200 Hz) steady sound, like a freezer compressor. Also described as a moan. Drumming A cycling, low-frequency (20-100 Hz), rhythmic noise often accompanied by a sensation of pressure on the eardrums. Also described as a low rumble, boom, or rolling thunder. Dynamic Balance Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8896 The equal distribution of weight on each side of the centerline, so that when the wheel and tire assembly spins, there is no tendency for the assembly to move from side-to-side (wobble). Dynamically unbalanced wheel and tire assemblies can cause wheel shimmy. Engine Imbalance A condition in which an engine's center mass is not concentric to the rotation center. Excessive motion. Engine Misfire When combustion in one or more cylinders does not occur or occurs at the wrong time. Engine Shake An exaggerated engine movement or vibration that directly increases in frequency as the engine speed increases. It is caused by non-equal distribution of mass in the rotating or reciprocating components. Flexible Coupling A flexible joint. Float A drive mode on the dividing line between cruise and coast where the throttle setting matches the engine speed with the road speed. Flutter Mid to high (100-200 Hz) intermittent sound due to air flow. Similar to a flag flapping in the wind. Frequency The rate at which a cycle occurs within a given time. Gravelly Feel A grinding or growl in a component, similar to the feel experienced when driving on gravel. Grind An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood. Hiss Steady high frequency (200-800 Hz) noise. Vacuum leak sound. Hoot A steady low frequency tone (50-500 Hz), sounds like blowing over a long neck bottle. Howl A mid-range frequency noise between drumming and whine. Hum Mid-frequency (200-800 Hz) steady sound, like a small fan motor. Also described as a howl. Hz Hertz; a frequency measured in cycles per second. Imbalance Out of balance; heavier on one side than the other. In a rotating component, imbalance often causes vibration. Inboard Toward the centerline of the vehicle. Intensity The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher the sound's amplitude, the higher the intensity and vice versa. Isolate To separate the influence of one component to another. Knock A heavy, loud, repetitious sound, like a knock on the door. Moan A constant, low-frequency (100-200 Hz) tone. Also described as a hum. Neutral Engine Run-Up (NERU) Test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8897 The operation of the engine through the normal rpm range with the vehicle standing still and the transmission disengaged. This test is used to identify engine related vibrations. Neutralize/Normalize To return to an unstressed position. Used to describe mounts. Refer to Bound Up. NVH Noise, vibration and harshness. A term used to describe conditions, which customers sense and result in varying degrees of dissatisfaction. Outboard Away from the centerline of the vehicle. Ping A short duration, high-frequency sound, which has a slight echo. Pinion Shaft The input shaft in a driving axle that is usually a part of the smaller driving or input hypoid gear of a ring and pinion gearset. Pitch The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice versa. Pumping Feel A slow, pulsing movement. Radial/Lateral Radial is in the plane of rotation; lateral is at 90 degrees to the plane of rotation. Rattle A random and momentary or short duration noise. Ring Gear The large, circular, driven gear in a ring and pinion gearset. Road Test The operation of the vehicle under conditions intended to produce the concern under investigation. Roughness A medium-frequency vibration. A slightly higher frequency (20 to 50 Hz) than a shake. This type of vibration is usually related to drivetrain components. Runout Out of round and wobble. Rustling Intermittent sound of varying frequency (100-200 Hz), sounds similar to shuffling through leaves. Shake A low-frequency vibration (5-20 Hz), usually with visible component movement. Usually relates to tires, wheels, brake drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to as a shimmy or wobble. Shimmy An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft rotation. Also described as waddle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8898 Shudder A low-frequency vibration that is felt through the steering wheel or seat during light brake application. Slap A resonance from flat surfaces, such as safety belt webbing or door trim panels. Slip Yoke/Slip Spline The driveshaft coupling that allows length changes to occur while the suspension articulates and while the driveshaft rotates. Squeak A high-pitched transient sound, similar to rubbing fingers against a clean window. Squeal A long-duration, high-pitched noise. Static Balance The equal distribution of weight around the wheel. Statically unbalanced wheel and tire assemblies can cause a bouncing action called wheel tramp. This condition will eventually cause uneven tire wear. Tap A light, rhythmic, or intermittent hammering sound, similar to tapping a pencil on a table edge. Thump A dull beat caused by two items striking together. Tick A rhythmic tap, similar to a clock noise. Tip-In Moan A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph). TIR Total indicated run out Tire Deflection The change in tire diameter in the area where the tire contacts the ground. Tire Flat Spots A condition commonly caused by letting the vehicle stand while the tires cool off. This condition can be corrected by driving the vehicle until the tires are warm. Also, irregular tire wear patterns in the tire tread resulting from wheel-locked skids. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8899 Tire Force Vibration A tire vibration caused by variations in the construction of the tire that is noticeable when the tire rotates against the pavement. This condition can be present on perfectly round tires because of variations in the inner tire construction. This condition can occur at wheel rotation frequency or twice rotation frequency. Transient Momentary, short duration. Two-Plane Balance Radial and lateral balance. Vibration Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and down. Whine A constant, high-pitched noise. Also described as a screech. Whistle High-pitched noise (above 500Hz) with a very narrow frequency band. Examples of whistle noises are a turbocharger or airflow around an antenna. Wind Noise Any noise caused by air movement in, out or around the vehicle. WOT Wide-open throttle Tools and Techniques Electronic Vibration Analyzer (EVA) The EVA is a hand-held electronic diagnostic tool which will assist in locating the source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle for testing purposes. The unit displays the three most common vibration frequencies and their corresponding amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength (amplitude) of each vibration being displayed and its relative G force. The keypad is arranged to make the EVA simple to program and use. Some of the functions include the ability to average readings as well as record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect imbalance on rotating components such as a driveshaft or engine accessories. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8900 The EVA allows for a systematic collection of information that is necessary to accurately diagnose and repair NVH problems. For the best results, carry out the test as follows: a. Test drive the vehicle with the vibration sensor inside the vehicle. b. Place the sensor in the vehicle according to feel. - If the condition is felt through the steering wheel, the source is most likely in the front of the vehicle. - A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle or rear wheels and tires. c. Record the readings. Also note when the condition begins when it reaches maximum intensity. and if it tends to diminish above/below a certain speed. - Frequencies should be read in the "avg" mode. - Frequencies have a range of plus or minus 2. A reading of 10 Hz can be displayed as an 8 Hz through 12 Hz. d. Determine what the normal frequency is for the vehicle at a specified speed. Multiply the rear axle ratio by the Hz (1 Hz per every 5 mph). Example: A vehicle travelling 50 mph with a 3.08 rear axle ratio, the acceptable amount of Hz for the vehicle at that speed would be 10 (1 Hz per every 5 mph) X 3.08 (rear axle ratio) = 30.8 Hz. e. Place the vibration sensor on or near the suspect area outside the vehicle. f. Continue the road test, driving the vehicle at the speed the symptom occurs, and take another reading. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8901 g. Compare the readings. - A match in frequency indicates the problem component or area. - An unmatched test could indicate the concern is caused by the engine, torque converter, or engine accessory. Use the EVA in the rpm mode and check if concern is rpm related. - Example: A vibration is felt in the seat, place the sensor on the console. Record the readings. Place the vibration sensor on the rear axle. Compare the readings. If the frequencies are the same, the axle is the problem component. Also refer to the following chart as a reference to acceptable vibration and noise ranges for the specified components. Vibrate Software(R) Vibrate software(R) (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the source of unacceptable vibrations. The Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8902 engine's crankshaft is the point of reference for vibration diagnosis. Every rotating component will have an angular velocity that is faster, slower, or the same as the engine's crankshaft. Vibrate software® calculates the angular velocity of each component and graphically represents these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how Vibrate software® helps diagnose a vibration concern: ^ Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire, driveshaft and engine vibrations. ^ Print a Vibration Worksheet graph. The printed graph is to be used during the road test. ^ Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration frequency (rpm) and the engine rpm on the worksheet graph. The point on the graph where the vibration frequency (rpm) reading and the engine rpm reading intersect indicates the specific component group causing the concern. - An EVA or equivalent tool capable of measuring vibration frequency and engine rpm will be needed. ^ Provides pictures of diagnostic procedures to aid in testing components. ChassisEAR An electronic listening device used to quickly identify noise and the location under the chassis while the vehicle is being road tested. The chassisEARs can identify the noise and location of damaged/worn wheel bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings. EngineEAR An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise of damaged/worn bearings in generators, water pumps, A/C compressors and power steering pumps. They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind noise. The EngineEAR has a sensing tip, amplifier, and headphones. The directional sensing tip is used to listen to the various components. Point the sensing tip at the suspect component and adjust the volume with the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and vibrations, generated by or passing through, the component. Various volume levels can reveal different sounds. Ultrasonic Leak Detector The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there is weather-stripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the source of the leak is approached, a beeping sound is produced which increases in both speed and frequency. Squeak and Rattle Repair Kit The squeak and rattle repair kit contains lubricants and self-adhesive materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the following materials: ^ PVC (soft foam) tape ^ Urethane (hard foam) tape ^ Flocked (black fuzzy) tape ^ UHMW (frosted) tape ^ Squeak and rattle oil tube Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8903 ^ Squeak and rattle grease tube Tracing Powder Tracing powder is used to check both the uniformity of contact and the tension of a seal against its sealing surface. These tests are usually done when a suspected air leak/noise appears to originate from the seal area or during the alignment and adjustment of a component to a weatherstrip. Tracing powder can be ordered from Crest Industries as ATR Leak Trace. Their toll-free number is 1-800-822-4100. Carry out the tracing powder test as follows: a. Clean the weatherstrip. b. Spray the tracing powder on the mating surface only. c. Close the door completely. Do not slam the door. d. Open the door. An imprint is made where the weatherstrip contacted the mating surface seal. Gaps or a faint imprint will show where there is poor contact with the weatherstrip. Dollar bill or 3x5 Card Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8904 Place a dollar bill or 3x5 card between the weatherstrip and the sealing surface, then close the door. Slowly withdraw the bill or 3x5 card after the door is closed and check the amount of pressure on the weatherstrip. There should be a medium amount of resistance as the dollar bill or 3x5 card is withdrawn. Continue around the entire seal area. If there is little or no resistance, this indicates insufficient contact to form a good seal. At these points, the door, the glass, or the weatherstrip is out of alignment. Diagnosis and Testing Noise, Vibration and Harshness (NVH) Special Service Tool(s) Diagnostic Process Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8905 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8906 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8907 To assist the service advisor and the technician, a Write-up Job Aid and an NVH Diagnostic Guide are included with this material. The Write-up Job Aid serves as a place to record all important symptom information. The NVH Diagnostic Guide serves as a place to record information reported on the Write-up Job Aid as well as data from the testing to be carried out. To begin a successful diagnosis, fill out the NVH Diagnostic Guide, record the reported findings, then proceed to each of the numbered process steps to complete the diagnosis. 1. Customer Interview The diagnostic process starts with the customer interview. The service advisor must obtain as much information as possible about the problem and take a test drive with the customer. There are many ways a customer will describe NVH concerns and this will help minimize confusion arising from descriptive language differences. It is important that the concern is correctly interpreted and the customer descriptions are recorded. During the interview, ask the following questions: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8908 ^ When was it first noticed? ^ Did it appear suddenly or gradually? ^ Did any abnormal occurrence coincide with or proceed it's appearance? Use the information gained from the customer to accurately begin the diagnostic process. 2. Pre-Drive Check It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle. The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything that will compromise safety during the road test and make those repairs/adjustments before taking the vehicle on the road. 3. Preparing For the Road Test Observe the following when preparing for the road test: ^ Review the information recorded on the NVH Diagnostic Guide. It is important to know the specific concern the customer has with the vehicle. ^ Do not be misled by the reported location of the noise/vibration. The cause can actually be some distance away. ^ Remember that the vibrating source component (originator) may only generate a small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another receiving component (reactor), due to contact with other components (transfer path). ^ Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in which the condition occurs. ^ If possible, lower the radio antenna in order to minimize turbulence. Identify anything that could potentially make noise or be a source of wind noise. Inspect the vehicle for add-on items that create vibration/noise. Turn off the radio and the heating and cooling system blower. ^ The engine speed is an important factor in arriving at a final conclusion. Therefore, connect an accurate tachometer to the engine, even if the vehicle has a tachometer. Use a tachometer that has clearly defined increments of less than 50 rpm. This ensures an exact engine speed reading. 4. Verify the Customer Concern Verify the customer concern by carrying out a road test, an engine run-up test, or both. The decision to carry out a road test, an engine run-up test, or both depends on the type of NVH concern. A road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A drive engine run-up (DERU) or a neutral engine run-up (NERU) test identifies noises and vibrations relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out these tests, however, they will eliminate many possibilities if carried out correctly. 5. Road Test Note: It may be necessary to have the customer ride along or drive the vehicle to point out the concern. During the road test. take into consideration the customer's driving habits and the driving conditions. The customer's concern just may be an acceptable operating condition for that vehicle. The following is a brief overview of each test in the order in which it appears. A review of this information helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this process. ^ The Slow Acceleration Test is normally the first test to carry out when identifying an NVH concern, especially when a road test with the customer is not possible. ^ The Heavy Acceleration Test helps to determine if the concern is torque-related. ^ The Neutral Coast Down Speed Test helps to determine if the concern is vehicle speed-related. ^ The Downshift Speed Test helps to determine if the concern is engine speed-related. ^ The Steering Input Test helps to determine how the wheel bearings and other suspension components contribute to a vehicle speed-related concern. ^ The Brake Test helps to identify vibrations or noise that are brake related. ^ The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy surface. ^ The Engine Run-Up Tests consist of the Neutral Run-up Test and the Engine Load Test. These tests help to determine if the concern is engine Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8909 speed-related. ^ The Neutral Run-up Test is used as a follow-up test to the Downshift Speed Test when the concern occurs at idle. ^ The Engine Load Test helps to identify vibration/noise sensitive to engine load or torque. It also helps to reproduce engine speed-related concerns that cannot be duplicated when carrying out the Neutral Run-up Test or the Neutral Coast Down Test. ^ The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-related concerns. ^ The Vehicle Cold Soak Procedure helps to identify concerns occurring during initial start-up and when an extended time lapse occurs between vehicle usage. Slow Acceleration Test To carry out this test, proceed as follows: ^ Slowly accelerate to the speed where the reported concern occurs. Note the vehicle speed, the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify from what part of the vehicle the concern is coming. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Heavy Acceleration Test To carry out this test, proceed as follows: ^ Accelerate hard from 0-64 km/h (0-40 mph). ^ Decelerate in a lower gear. ^ The concern is torque related if duplicated while carrying out this test. ^ Proceed as necessary. Neutral Coast Down Speed Test To carry out this test, proceed as follows: ^ Drive at a higher rate of speed than where the concern occurred when carrying out the Slow Acceleration Test. ^ Place the transmission in NEUTRAL and coast down past the speed where the concern occurs. ^ The concern is vehicle speed-related if duplicated while carrying out this test. This eliminates the engine and the torque converter as sources. ^ If the concern was not duplicated while carrying out this test, carry out the Downshift Speed Test to verify if the concern is engine speed related. ^ Proceed as necessary. Downshift Speed Test To carry out this test, proceed as follows: ^ Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test. ^ Drive at the engine rpm where the concern occurs. ^ The concern is engine speed related if duplicated while carrying out this test. This eliminates the tires, wheels, brakes and the suspension components as sources. ^ If necessary, repeat this test using other gears and NEUTRAL to verify the results. ^ Proceed as necessary. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8910 Steering Input Test To carry out this test, proceed as follows: ^ Drive at the speed where the concern occurs, while making sweeping turns in both directions. ^ If the concern goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of 4WD applications), and tire tread wear are all possible sources. ^ Proceed as necessary. Brake Test To carry out this test, proceed as follows: ^ Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking applications. At highway speeds of 89-97 km/h (50-60 mph), apply the brake using a light pedal force. ^ Accelerate to 89-97 km/h (55-60 mph). ^ Lightly apply the brakes and slow the vehicle to 30 km/h (20 mph). ^ A brake vibration noise can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard upon brake application and diminish when the brake is release. Road Test Over Bumps To carry out this test, proceed as follows: ^ Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is coming from the front or the back and the left or the right side of the vehicle. ^ Proceed as necessary. Neutral Engine Run-up (NERU) Test To carry out this test, proceed as follows: ^ In stall a tachometer. ^ Increase the engine rpm up from an idle to approximately 4000 rpm while in PARK on front wheel drive vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the engine rpm and, if possible, determine the vibration frequency. ^ Attempt to identify what part of the vehicle the concern is coming from. ^ Attempt to identify the source of the concern. ^ Proceed as necessary. Drive Engine Run-up (DERU) Load Test To carry out this test, proceed as follows: ^ WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. ^ CAUTION: Do not carry out the Engine Load Test for more than five seconds or damage to the transmission or transaxle can result. Block the front and rear wheels. ^ Apply the parking brake and the service brake. ^ Install a tachometer. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8911 ^ Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to approximately 2000 rpm. Note the engine rpm and, if possible, determine the vibration frequency. ^ Repeat the test in REVERSE. ^ If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or transaxle mounts. ^ If the concern is definitely engine speed-related, carry out the Engine Accessory Test to narrow down the source. ^ Proceed as necessary. Engine Accessory Test To carry out this test, proceed as follows: WARNING: Block the front and rear wheels, and apply the parking brake and the service brake, or injury to personnel can result. CAUTION: Limit engine running time to one minute or less with belts removed or serious engine damage will result. Note: A serpentine drive belt decreases the usefulness of this test. In these cases. use a vibration analyzer, such as the EVA, to pinpoint accessory vibrations. An electronic listening device. such as an EngineEAR, will also help to identify noises from specific accessories. Remove the accessory drive belts. ^ Increase the engine mm to where the concern occurs. ^ If the vibration/noise is duplicated when carrying out this test. the belts and accessories are not sources. ^ If the vibration/noise was not duplicated when carrying out this test, install each accessory belt, one at a time, to locate the source. Vehicle Cold Soak Procedure To carry out this procedure, proceed as follows: ^ Test preparations include matching customer conditions (if known). If not known, document the test conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to three minutes. ^ Park the vehicle where testing will occur. The vehicle must remain at or below the concern temperature (if known) for 6-~ hours. ^ Before starting the engine, conduct a visual inspection under the hood. ^ Turn the key on. but do not start the engine. Listen for the fuel pump. anti-lock brake system (ABS) and air suspension system noises. ^ Start the engine. ^ CAUTION: Never probe moving parts. Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the general location of the vibration/noise. Then, search for a more precise location by using a stethoscope or EngineEAR. ^ Refer to Idle Noise/Vibration in the Symptom Chart to assist with the diagnosis. 6. Check OASIS/TSBs/Repair History After verifying the customer concern, check for OASIS reports, TSBs and the vehicle repair history for related concerns. If information relating to a diagnosis/repair is found, carry out the procedure(s) specified in that information. If no information is available from these sources, carry out the vehicle preliminary inspection to eliminate any obvious faults. 7. Diagnostic Procedure Qualifying the concern by the particular sensation present can help narrow down the concern. Always use the "symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the problem into related areas to correct the customer concern. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8912 ^ Verify the "symptom". ^ Determine which "system(s)" can cause the "symptom". - If a vibration concern is vehicle speed related. the tire and wheel rpm/frequency or driveshaft frequency should be calculated. - If a vibration concern is engine speed related. the engine, engine accessory or engine firing frequencies should be calculated. ^ After determining the "system", use the diagnostic tools to identify the worn or damaged 'components". ^ After identifying the "components". try to find the "cause" of the failure. Once the concern is narrowed down to a symptom/condition. proceed to NVH Condition and Symptom Categories. Operating Condition - Vehicle Is Not Moving 1. Static operation ^ Noise occurs during part/system functioning. GO to Symptom Chart - Squeak and Rattle. 2. While cranking 1. Grinding or whine, differential ring gear or starter motor pinion noise. GO to Symptom Chart Engine Noise/Vibration. 2. Rattle. Exhaust hanger, exhaust heat shield or A/C line noise. GO to Symptom Chart - Squeak and Rattle. 3. Vibration. Acceptable condition. 3. At idle ^ Idle noise. GO to Symptom Chart - Idle Noise/Vibration. ^ Idle vibration or shake. GO to Symptom Chart - Idle Noise/Vibration. 4. During Gear Selection 1. Vehicle parked on a steep incline. Acceptable noise. 2. Vehicle parked on a flat surface. GO to Symptom Chart - Driveline Noise/Vibration. 3. Vehicle with a manual transmission. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. Operating Condition - Vehicle Is Moving 1. Depends more on how the vehicle is operated 1. Speed related ^ Related to vehicle speed - Pitch increases with vehicle speed. GO to Symptom Chart - Tire Noise/Vibration. - Noise occurs at specific vehicle speed. A high-pitch noise (whine). GO to Symptom Chart Driveline Noise/Vibration. - Loudness proportional to vehicle speed. Low-frequency noise at high speeds, noise and loudness increase with speed. GO to Symptom Chart - Driveline Noise/Vibration. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8913 - A low-pitched noise (drumming). GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of acceleration or deceleration. GO to Symptom Chart Tire Noise/Vibration. - Noise varies with wind/vehicle speed and direction. GO to Symptom Chart Air Leak and Wind Noise. ^ Related to engine speed. - Noise varies with engine rpm. GO to Symptom Chart - Engine Noise/Vibration. - Vibration occurs at a particular speed (mph) regardless of engine speed (rpm). 2. Acceleration ^ Wide open throttle (WOT) - Engine induced contact between components. Inspect and repair as necessary. - Noise is continuous throughout WOT. Exhaust system or engine ground out. GO to Symptom Chart - Engine Noise/Vibration. ^ Light/moderate acceleration - Tip-in moan. Engine/exhaust noise. GO to Symptom Chart - Engine Noise/Vibration. - Knock-type noise. GO to Symptom Chart - Engine Noise/Vibration. - Driveline shudder. GO to Symptom Chart - Driveline Noise/Vibration. - Engine vibration. GO to Symptom Chart - Engine Noise/Vibration. 3. Turning noise. GO to Symptom Chart - Steering Noise/Vibration. 4. Braking. ^ Clicking sound is signaling ABS is active. Acceptable ABS sound. ^ A continuous grinding/squeal. GO to Symptom Chart - Brake Noise/Vibration. ^ Brake vibration/shudder. GO to Symptom Chart - Brake Noise/Vibration. 5. Clutching ^ A noise occurring during clutch operation. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. ^ Vibration. GO to Symptom Chart - Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8914 Transmission (Manual) and Transfer Case Noise/Vibration. 6. Shifting ^ Noise or vibration condition related to the transmission (automatic). GO to Symptom Chart Transmission (Automatic) Noise/Vibration. ^ Noise or vibration related to the transmission (manual). GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 7. Engaged in four-wheel drive. GO to Symptom Chart - Transmission (Manual) and Transfer Case Noise/Vibration. 8. Cruising speeds ^ Accelerator pedal vibration. GO to Symptom Chart - Engine Noise/Vib ration. ^ Driveline vibration. GO to Symptom Chart - Driveline Noise/Vibration. ^ A shimmy or shake. GO to Symptom Chart - Tire Noise/Vibration. 9. Driving at low/medium speeds ^ A wobble or shudder. GO to Symptom Chart - Tire Noise/Vibration. 2. Depends more on where the vehicle is operated 1. Bump/pothole, rough road or smooth road. GO to Symptom Chart - Suspension Noise/Vibration. ^ Noise is random or intermittent occurring from road irregularities. GO to Symptom Chart - Squeak and Rattle. ^ Noise or vibration changes from one road surface to another. Normal sound changes. ^ Noise or vibration associated with a hard/firm ride. GO to Symptom Chart - Suspension Noise/Vibration. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8915 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8916 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8917 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8918 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8919 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8920 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8921 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8922 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8923 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8924 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8925 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8926 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8927 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8928 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8929 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8930 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8931 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8932 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8933 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8934 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8935 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8936 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8937 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8938 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8939 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8940 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8941 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8942 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8943 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8944 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8945 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8946 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8947 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8948 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8949 Pinpoint Tests The pinpoint tests are a step-by-step diagnostic process designed to determine the cause of a condition. It may not always be necessary to follow a pinpoint test to its conclusion. Carry out only the steps necessary to correct the condition. Then, test the system for normal operation. Sometimes, it is necessary to remove various vehicle components to gain access to the component requiring testing. For additional information, REFER to the appropriate Workshop Manual section for removal and installation procedures. Reinstall all components after verifying system operation is normal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8950 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8951 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8952 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8953 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8954 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8955 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8956 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8957 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8958 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8959 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8960 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8961 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8962 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8963 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8964 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8965 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8966 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8967 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8968 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8969 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8970 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8971 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8972 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8973 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8974 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8975 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8976 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8977 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8978 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8979 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8980 Idle Speed Air Control Valve (ISACV) 1. Open the hood. 2. Note: Key symptom is elevated idle speed while noise is occurring. Note: "Snapping" the throttle can induce the noise. Verify the condition by operating the vehicle for a short time. 3. Inspect the ISACV. If physical evidence of contamination exists, install a new ISACV. 4. While the noise is occurring, either place an EngineEAR probe near the ISACV and the inlet tube, or create a 6.35 mm (0.25 in)-12.7 mm (0.50 in) air gap between the inlet tube and the clean air tube. If the ISACV is making the noise, install a new ISACV. 5. Test the vehicle for normal operation. Steering Gear Grunt/Shudder Test 1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at a time. Damage to the power steering pump will occur. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8981 Rotate the steering wheel to the RH stop. then turn the steering wheel 90° back from that position. Turn the steering wheel slowly in a 15° to 30° arc. 4. Turn the steering wheel another 90°. Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50-200Hz) shudder is present, this is a normal steering system condition. Checking Tooth Contact Pattern/Condition of Ring & Pinion There are two basic types of conditions that will produce ring and pinion noise. The first type is a howl or chuckle produced by broken, cracked, chipped, scored or forcibly damaged gear teeth and is usually quite audible over the entire speed range. The second type of ring and pinion noise pertains to the mesh pattern of the gear pattern. This gear noise can be recognized as it produces a cycling pitch or whine. Ring and pinion noise tends to peak in a narrow speed range or ranges, and will tend to remain constant in pitch. 1. Raise and support the vehicle. 2. Drain the axle lubricant. Refer to the appropriate workshop manual for the draining procedures. 3. Remove the carrier assembly or the axle housing cover depending on the axle type. Refer to the appropriate workshop manual for the service procedures. 4. Inspect the gear set for scoring or damage. 5. In the following steps, the movement of the contact pattern along the length is indicated as toward the "heel" or "toe" of the differential ring gear. 6. Apply a marking compound to a third of the gear teeth on the differential ring gear. Rotate the differential ring gear several complete turns in both directions until a good, clear tooth pattern is obtained. Inspect the contact patterns on the ring gear teeth. 7. A good contact pattern should be centered on the tooth. It can also be slightly toward the toe. There should always he some clearance between the contact pattern and the top of the tooth. Tooth contact pattern shown on the drive side of the gear teeth. 8. A high, thick contact pattern that is worn more toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The high contact pattern indicates that the drive pinion is not installed deep enough into the carrier. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8982 ^ The differential ring gear backlash is correct, a thinner drive pinion shim is needed. A decrease will move the drive pinion toward the differential ring gear. 9. A high, thin contact pattern that is worn toward the toe. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The drive pinion depth is correct. Increase the differential ring gear backlash. 10. A contact pattern that is worn in the center of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. ^ The low contact pattern indicates that the drive pinion is installed too deep into the carrier. ^ The differential ring gear backlash is correct. A thicker drive pinion shim is needed. 11. A contact pattern that is worn at the top of the differential ring gear tooth toward the heel. ^ Tooth contact pattern shown on the drive side of the gear teeth. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8983 ^ The pinion gear depth is correct. Decrease the differential ring gear backlash. Tire Wear Patterns & Frequency Calculations Wheel and tire NVH concerns are directly related to vehicle speed and are not generally affected by acceleration, coasting or decelerating. Also, out-of-balance wheel and tires can vibrate at more than one speed. A vibration that is affected by the engine rpm or is eliminated by placing the transmission in NEUTRAL is not related to the tire and wheel. As a general rule, tire and wheel vibrations felt in the steering wheel are related to the front tire and wheel assemblies. Vibrations felt in the seat or floor are related to the rear tire and wheel assemblies. This can initially isolate a concern to the front or rear. Careful attention must be paid to the tire and wheels. There are several symptoms that can~be caused by damaged or worn tire and wheels. Carry out a careful visual inspection of the tires and wheel assemblies. Spin the tires slowly and watch for signs of lateral or radial runout. Refer to the tire wear chart to determine the tire wear conditions and actions. For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and wheel rpm and frequency by carrying out and following: ^ Measure the diameter of the tire. ^ Record the speed at which the vibration occurs. Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency Chart. - If the vehicle speed is not listed, divide the vehicle speed at which the vibration occurs by 16 (km/h (10 mph). Multiply that number by 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide that number by 60. For example: a 40 mph vibration with 835 mm (33 in) tires. 40 divided by 10 = 4. Multiply 4 by 105 = 420 rpm. Divide 420 rpm by 60 seconds = 7 Hz at 40mph. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8984 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8985 Powertrain/Drivetrain Mount Neutralizing WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. Raise and support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners. 3. Lower the vehicle. 4. CAUTION: Do not twist or strain the powertrain/drivetrain mounts. Move the vehicle in forward and reverse (2-4 ft). 5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the vehicle. 8. Test the system for normal operation. Exhaust System Neutralizing WARNING: Exhaust gases contain carbon monoxide, which is harmful to health and potentially lethal. Repair exhaust system leaks immediately. Never operate the engine in an enclosed area. WARNING: Exhaust system components are hot. Note: Neutralize the exhaust system to relieve strain on mounts which can be sufficiently bound up to transmit vibration as if grounded. 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8986 CAUTION: Make sure the system is warmed up to normal operating temperature, as thermal expansion can he the cause of a strain problem. Raise and support the vehicle. 2. Loosen all exhaust hanger attachments and reposition the hangers until they hang free and straight. 3. Loosen all exhaust flange joints. 4. Place a stand to support the muffler parallel to the vehicle frame with the muffler pipe bracket free of stress. 5. Tighten the muffler connection. 6. Tighten all the exhaust hanger clamps and flanges (tighten the exhaust manifold flange joint last). ^ Verify there is adequate clearance to prevent grounding at any point in the system. Make sure that the catalytic converter and heat shield do not contact the frame rails. ^ After neutralization. the rubber in the exhaust hangers should show some flexibility when movement is applied to the exhaust system. ^ With the exhaust system installed securely and cooled. the rear hanger should be angled forward. 7. Lower the vehicle. 8. Test the exhaust system for normal operation. Wheel Bearing Check 1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Raise the vehicle until the front tires are off the floor. ^ Make sure the wheels are in a straight forward position. 2. Note: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow free movement of the tire and wheel assembly. Spin the tire by hand to check the wheel bearings for roughness. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Technical Service Bulletins > Comprehensive Noise/Vibration/Harshness Procedure > Page 8987 3. Grip each front tire at the top and bottom and move the wheel inward and outward while lifting the weight of the tire off the front wheel bearing. 4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling when spun, carry out one of the following: ^ On vehicles with inner and outer bearings, Inspect the bearings and cups for wear or damage. Adjust or install new bearings and cups as necessary. ^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the appropriate workshop manual for the service procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Mechanical Specifications Wheel Bearing: Mechanical Specifications Maximum Axle Shaft End Play 0.762 mm Maximum Axle Shaft End Play 0.762 mm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Mechanical Specifications > Page 8990 Wheel Bearing: Fluid Type Specifications 8.8 Inch Ring Gear - Lubricate the new rear wheel bearing. Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. - Lubricate the lip of the new inner wheel bearing oil seal. Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 9.75 Inch Ring Gear - Lubricate the new rear wheel bearing. Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. - Lubricate the lip of the new inner wheel bearing oil seal. Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 8991 Wheel Bearing: Service Precautions CAUTION: Use only a grease that is recommended for wheel bearing applications. Use of the improper grease can cause bearing damage. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > 8.8-Inch Ring Gear Wheel Bearing: Service and Repair 8.8-Inch Ring Gear Special Tools Special Tools Removal 1. Remove the axle shaft. 2. NOTE: If the inner wheel bearing oil seal is leaking, the rear axle housing vent may be plugged. Using the special tools, remove the rear axle bearing and inner wheel bearing oil seal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > 8.8-Inch Ring Gear > Page 8994 Installation 1. Lubricate the new rear wheel bearing. - Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 2. Use the special tools to install the rear wheel bearing. 3. Lubricate the lip of the new inner wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tools, install the inner wheel bearing oil seal. 5. Install the axle shaft. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > 8.8-Inch Ring Gear > Page 8995 Wheel Bearing: Service and Repair 9.75-Inch Ring Gear Special Tools Special Tools Removal 1. Remove the axle shaft. 2. NOTE: If the inner wheel bearing oil seal is leaking, the rear axle housing vent may be plugged. Using the special tools, remove the rear wheel bearing and inner wheel bearing oil seal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > 8.8-Inch Ring Gear > Page 8996 Installation 1. Lubricate the new rear wheel bearing. - Use Motorcraft Synthetic Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification WSL-M2C192-A. 2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new inner wheel bearing oil seal. - Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B. 4. Using the special tools, install the inner wheel bearing oil seal. 5. Install the axle shafts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Page 8997 Wheel Bearing: Tools and Equipment Special Tools Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications TORQUE SPECIFICATIONS Front Axle Hub Nut ........................................................................................................................................................... 255-345 Nm (188-254 ft. lbs.) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications Wheel Fastener: Specifications TORQUE SPECIFICATIONS CAUTION: Failure to tighten the lug nuts in a star pattern can result in high brake disc runout, which will speed up the development of brake roughness, shudder and vibration. Tighten the lug nuts in sequence to 113-153 Nm (83-112 ft. lbs.). GENERAL SPECIFICATIONS Wheel Stud and Lug Nut: M12 x 1.75 - 19mm hex Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Wheel Fastener: Service and Repair Front Removal WARNING: The electrical power to the air suspension system must be turned off prior to hoisting, jacking or towing an air suspension vehicle. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. 1. If equipped, turn the air suspension service switch off. 2. Raise the vehicle on a hoist. 3. Remove the wheel and tire assembly. 4. Remove the front disc brake hub and brake disc. 5. Using a suitable press, remove the wheel stud from the front disc brake hub and brake disc. Installation 1. Follow the removal procedure in reverse order. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 9007 Wheel Fastener: Service and Repair Rear Special Tool(s) Removal CAUTION: Never use a hammer to remove the lug bolt. Damage to the axle flange, hub flange, wheel bearing or hub bearing can result. 1. WARNING: The electrical power to the air suspension system must be turned off prior to hoisting, jacking or towing an air suspension vehicle. Failure to do so can result in unexpected inflation or deflation of the air springs and/or shocks which can result in shifting of the vehicle during these operations. Turn the air suspension service switch off, if so equipped. 2. Raise the vehicle and install safety stands. 3. Remove the wheel and tire assembly. 4. Remove the rear disc brake caliper, rear disc support bracket and brake disc if so equipped. Support rear disc brake caliper with safety wire. If drum brake, proceed to Step 5. 5. Remove the rear brake drum. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 9008 6. Using C-Frame and Clamp Assembly Tool, press the lug bolt from its seat and discard. Installation CAUTION: Never use air tools to install lug bolts. The serrations can be stripped from the stud. 1. Insert a new wheel stud in the hole in the axle flange or hub flange, making sure serrations are aligned with those made by the original lug bolt. 2. Seat new wheel stud in axle flange or hub flange. ^ Place four flatwashers over the outside end of the wheel stud. ^ Thread a standard lug nut with the flat side against the washers. ^ Tighten the lug nut until the wheel stud head seats against the back side of the flange. 3. Remove the lug nut and flatwashers. 4. Install the brake disc, rear disc support bracket and the rear disc brake caliper, if so equipped. If drum brake, proceed to Step 5. 5. Install the rear brake drum. 6. Install the wheel and tire assembly. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front > Page 9009 7. Lower the vehicle. 8. Turn the air suspension service switch on, if so equipped. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Page 9010 Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications Accumulator HVAC: Specifications Suction Accumulator Bracket Bolt ............................................................................................................................................... 9-11.2 N.m (80-100 Lb-In) Suction Accumulator Fitting ..................................................................................................................................................... 25.5-34.5 N.m (19-25 Lb-Ft) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 9015 Accumulator HVAC: Description and Operation An A/C evaporator core orifice or O-ring seal is not considered a major component, but the A/C evaporator core orifice should be replaced whenever the A/C compressor is replaced for lack of performance. The suction accumulator/drier is mounted to the A/C accumulator bracket to the right of the vehicle centerline. The inlet tube of the suction accumulator/drier attaches directly to the A/C evaporator core outlet tube and the outlet tube of the suction accumulator/drier attaches to the A/C manifold and tube. After entering the inlet of the suction accumulator/drier, heavier oil-laden refrigerant contacts an internally mounted dome (which serves as an umbrella) and drips down onto the bottom of the canister. - A small diameter oil bleed hole, in the bottom of the vapor return tube, allows the accumulated heavier liquid refrigerant and oil mixture to re-enter the compressor suction line at a controlled rate. - As the heavier mixture passes through the small diameter liquid bleed hole, it has a second chance to vaporize and recirculate through the A/C compressor without causing compressor damage due to slugging. - A fine mesh screened filter fits tightly around the bottom of the vapor return tube to filter out refrigerant system contaminant particles. - A desiccant bag is mounted inside the canister to absorb any moisture which may be in the refrigerant system. - A fitting located on the top of the suction accumulator/drier is used to attach the A/C cycling switch. A long-travel Schrader-type valve stem core Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 9016 is installed in the fitting so that the A/C cycling switch can be removed without discharging the A/C system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 9017 Accumulator HVAC: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the junction block splash shield. 3. Remove the two cable ends from the starter relay. 4. Remove the two bolts and reposition the junction block bracket. 5. Recover the refrigerant. See: Service and Repair/Refrigerant Recovery 6. Disconnect the A/C cycling switch electrical connector. 7. Disconnect the manifold and tube fitting. CAUTION: Use a backup wrench to prevent damage to the tubes. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 9018 8. Remove the accumulator bracket clamping bolt. 9. Disconnect the suction accumulator/drier spring lock coupling from the A/C evaporator core. 10. Remove the suction accumulator/drier. 11. Remove the A/C cycling switch from the top of the suction accumulator/drier. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications > Page 9019 1. Follow the removal procedure in reverse order. - Service the replacement suction accumulator/drier with the correct amount of YN-12c Motorcraft Oil or equivalent meeting Ford specification WSH-M1C231-B. - Apply Pipe Sealant with Teflon (R) D8AZ-19554-A or equivalent meeting Ford specifications WSK-M20350-A2 and ESR-M18P7-A to the threads of the A/C manifold retaining bolt. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Door Actuator Air Door Actuator / Motor: Service and Repair Air Door Actuator Air Inlet Door REMOVAL 1. Remove the plenum chamber. 2. Remove the air inlet door vacuum control motor. 1 Disconnect the vacuum line. 2 Remove the screws. 3 Remove the air inlet door vacuum control motor. Rotate the vacuum control motor to disconnect the vacuum control motor rod from air inlet door lever. INSTALLATION 1. To install, reverse the removal procedure. Panel/Defrost Door REMOVAL 1. Remove the panel/defrost door vacuum control motor. 1 Disconnect the vacuum line. 2 Remove the push nut. 3 Remove the screws. 4 Remove the panel/defrost door vacuum control motor. INSTALLATION 1. To install, reverse the removal procedure. Panel/Floor Door REMOVAL Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Door Actuator > Page 9026 1. Remove the floor duct panel. - Remove the pushpins and release the expander clip. 2. Remove the RH instrument panel brace. 1 Remove the nut. 2 Remove the bolt. 3 Remove the brace. 3. Remove the LH instrument panel lower nut and position the brace aside. 4. Remove the three bolts and position the module aside. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Door Actuator > Page 9027 5. Remove the floor duct. 1 Remove the two screws (one each side). 2 Remove the floor duct. 6. Remove the panel/floor door vacuum control motor. 1 Disconnect the vacuum line connector. 2 Remove the screws. 3 Slide the rod out of the door and remove the panel/floor door vacuum control motor. NOTE: Rotate the vacuum control motor to disconnect the vacuum control motor rod from the panel/floor door. INSTALLATION 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Door Actuator > Page 9028 Air Door Actuator / Motor: Service and Repair Blend Door Motor REMOVAL 1. Remove the floor duct panel. - Remove the pushpins and release the expander clip. 2. Remove the RH instrument panel brace. 1 Remove the nut. 2 Remove the bolt. 3 Remove the brace. 3. Remove the LH instrument panel lower nut and position the brace aside. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Door Actuator > Page 9029 4. Remove the three bolts and position the module aside. 5. Remove the floor duct. 1 Remove the two screws (one each side). 2 Remove the floor duct. 6. Remove the panel/floor door vacuum control motor. 1 Disconnect the vacuum line connector. 2 Remove the screws. 3 Slide the rod out of the door and remove the panel/floor door. NOTE: Rotate the vacuum control motor to disconnect the vacuum control motor rod from the panel/floor door. 7. Remove the electronic blend door actuator. 1 Disconnect the connector. 2 Remove the screws. 3 Pull down to release the actuator shaft and remove the electronic blend door actuator. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Door Actuator > Page 9030 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Specifications Air Duct: Specifications Demister Screw ................................................................................................................................... ................................................ 2-3 N.m (18-26 Lb-In) A/C plenum demister adapter screw .................................................................................................................................................... 2-3 N.m (18-27 Lb-In) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defrost Nozzles and Side Demister Duct Air Duct: Service and Repair Defrost Nozzles and Side Demister Duct REMOVAL 1. Remove the plenum chamber. 2. Remove the A/C plenum demister adapter. 1 Remove the screw. 2 Remove the A/C plenum demister adapter. 3. Remove the demister nozzle and duct. 1 Remove the screws. 2 Remove the demister nozzle and duct. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defrost Nozzles and Side Demister Duct > Page 9036 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defrost Nozzles and Side Demister Duct > Page 9037 Air Duct: Service and Repair Floor Duct REMOVAL 1. Remove the floor duct panel. - Remove the two plastic pushpins (one on each side) and release the expander clip. 2. Remove the RH instrument panel brace. 1 Remove the nut. 2 Remove the bolt. 3 Remove the brace. 3. Remove the LH instrument panel lower nut and position the brace aside. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Defrost Nozzles and Side Demister Duct > Page 9038 4. Remove the restraint module bolts and position them aside. 5. Remove the floor duct. 1 Remove the two screws. 2 Remove the floor duct. INSTALLATION 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Specifications Air Register: Specifications RH Instrument Panel Brace ................................................................................................................. ........................................................ 8 N.m (71 Lb-In) LH Instrument Panel Brace ............................. ............................................................................................................................................. 8 N.m (71 Lb-In) LH Instrument Panel Nut ........................................................................................................... .................................................................. 8 N.m (71 Lb-In) RH Instrument Panel Brace Bolt ........... ...................................................................................................................................................... 8 N.m (71 Lb-In) RH Instrument Panel Brace Nut .................................................................................. ................................................................................ 8 N.m (71 Lb-In) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Center Air Register: Service and Repair Center REMOVAL 1. Remove the center instrument panel finish panel. 2. If equipped, disconnect the transfer case rotary control switch electrical connector. 3. Disconnect the battery. WARNING: NEVER PROBE THE CONNECTIONS ON THE AIR BAGS. DOING SO MAY RESULT IN AIR BAG DEPLOYMENT WHICH COULD RESULT IN PERSONAL INJURY. - THE BACKUP POWER SUPPLY MUST BE DEPLETED BEFORE SERVICING OR REPLACING ANY AIR BAG SYSTEM COMPONENTS. FAILURE TO DEPLETE THE BACKUP POWER SUPPLY MAY ACCIDENTLY DEPLOY THE AIR BAG AND CAUSE PERSONAL INJURY. 4. If equipped, disconnect the passenger air bag defeat switch electrical connector. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Center > Page 9044 5. Remove the center panel register. 1 Remove the screws. 2 Pry back the lock tabs. 3 Remove the panel register. INSTALLATION 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Center > Page 9045 Air Register: Service and Repair Left REMOVAL 1. Remove the steering column cover panel. 2. Remove the headlamp switch. 3. Remove the LH instrument panel finish panel. 1 Remove the screws. 2 Remove the instrument panel finish panel. 4. Remove the LH panel register. 1 Remove the screws. 2 Pry back the lock tabs. 3 Remove the LH panel register. INSTALLATION 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Center > Page 9046 Air Register: Service and Repair Right REMOVAL 1. Remove the instrument panel. 2. Remove the RH panel register. 1 Remove the screws. 2 Remove the RH panel register. INSTALLATION 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Specifications Blower Motor: Specifications Blower Motor Screws ........................................................................................................................... ........................................... 2-3.5 N.m (18-31 Lb-In) Blower Motor Cover Screws ............................. .................................................................................................................................... 1-2 N.m (9-17 Lb-In) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Specifications > Page 9050 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Specifications > Page 9051 Blower Motor: Description and Operation Blower Motor The A/C blower motor pulls air from the air inlet and forces it into the plenum assembly where it is mixed and distributed. The A/C blower motor has four speeds and is controlled by the blower motor switch and resistor. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Specifications > Page 9052 Blower Motor: Service and Repair REMOVAL 1. If equipped, remove the aftermarket air filter. 2. If equipped, remove the mounting bracket for the removed cover. 3. Disconnect the Christmas tree retainer from the motor mounting plate. 4. Disconnect the connector. 5. Remove the blower motor cover. 1 Remove the three screws. 2 Pry to release the three tabs. 3 Remove the cover. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Specifications > Page 9053 6. Remove the blower motor. 1 Remove the three screws. 2 Remove the blower motor. CAUTION: Carefully remove the blower motor to avoid damage to the wheel. 7. Remove the wheel from the blower motor. 1 Remove the push clip. 2 Remove the wheel. 8. Remove the gasket. INSTALLATION 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Diagrams > Page 9060 Blower Motor Resistor: Description and Operation The heater blower motor switch resistor has the following features: - The assembly is located on the passenger side of the plenum assembly behind the glove compartment. - Three resistance elements are mounted on the resistor board to provide four A/C blower motor speeds. - Depending on the heater blower motor switch position, series resistance is added or bypassed in the A/C blower motor circuit to decrease or increase A/C blower motor speed. Blower Motor Resistor Coils Blower Motor Thermal Limiter - An overheating protective device (thermal limiter) will open the resistor coil circuit when the temperature reaches 121°C (250°F), interrupting the blower motor operation in all speeds except HI. - The thermal limiter cannot be reset and is not serviceable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and Repair Cabin Air Filter: Service and Repair Note: Not all of these vehicles were equipped with a Cabin Air Filter. Only vehicles with a filter cover in the location shown have a Cabin Air Filter Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications Compressor Clutch: Specifications A/C Clutch Air Gap ........................................................................................................................................................... 0.35-0.85 mm (0.014-0.033 Inch) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 9068 Compressor Clutch: Description and Operation NOTE: - Internal A/C compressor components are not serviced separately. The FS-10 A/C compressor is serviced only as an assembly. The A/C clutch, A/C clutch pulley, A/C clutch field coil and the shaft seal are serviceable. - Whenever the A/C compressor is replaced, also replace the A/C evaporator core orifice. Compressor Clutch Components The magnetic A/C clutch has the following characteristics: - It drives the compressor shaft. - When battery positive voltage (B+) is applied to the A/C clutch field coil, the clutch plate and hub assembly is drawn toward the A/C clutch pulley . - The magnetic force locks the clutch plate and hub assembly and the A/C clutch pulley together as one unit, causing the compressor shaft to rotate. - When B+ is removed from the A/C clutch field coil, springs in the clutch plate and hub assembly move the clutch plate away from the A/C clutch pulley. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 9069 Compressor Clutch: Adjustments 1. Check the A/C clutch air gap at three equally spaced places between the clutch hub and the A/C clutch pulley. 2. Remove the A/C clutch. Add or remove spacers between the A/C clutch and the compressor shaft until clearance is within specification. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 9070 Compressor Clutch: Service and Repair SPECIAL TOOL(S) REMOVAL 1. Remove the A/C compressor. 2. Remove the A/C clutch hub retaining bolt. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 9071 1 Hold the A/C clutch hub with the Compressor Clutch Holding Tool. 2 Remove the bolt. 3. Remove the A/C clutch and the A/C clutch hub spacer. 1 Thread an 8 x 1.25 mm bolt into the A/C clutch hub spacer to force it from the compressor shaft. 2 Lift the A/C clutch and the A/C clutch hub spacer from the compressor shaft. 4. Remove the pulley snap ring. 5. Remove the A/C clutch pulley. 6. Remove the A/C clutch field coil. 1 Note the location of the A/C clutch field coil electrical connector. 2 Install the Field Coil Remover on the nose opening of the A/C compressor. 3 Install the Differential Bearing Cone Remover. 4 Remove the A/C clutch field coil. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 9072 CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. INSTALLATION 1. Clean the A/C clutch field coil and the pulley bearing mounting surfaces. 2. Install the A/C clutch field coil. 1 Place the A/C clutch field coil on the A/C compressor with the A/C clutch field coil electrical connector properly positioned. 2 Place the Field Coil Replacer on the A/C clutch field coil. 3 Place the Coil Replacer on the Field Coil Replacer. 4 Use the 2-Jaw Puller to install the A/C clutch field coil until bottomed completely against the A/C compressor. CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. 3. Install the A/C clutch pulley. NOTE: The A/C clutch pulley is a tight fit on the A/C compressor head; it must be properly aligned during installation. 4. Install the pulley snap ring with the bevel side out. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Page 9073 5. Place one nominal thickness A/C clutch hub spacer inside the clutch hub spline opening. 6. Install the A/C clutch. 7. Install the A/C clutch hub retaining bolt. 1 Hold the A/C clutch hub with the Compressor clutch Holding Tool. 2 Tighten the bolt. 8. Measure and adjust the clutch air gap by removing or adding the A/C clutch hub spacer. 9. Install the A/C compressor. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair Compressor Clutch Coil: Service and Repair SPECIAL TOOL(S) REMOVAL 1. Remove the A/C compressor. 2. Remove the A/C clutch hub retaining bolt. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Page 9077 1 Hold the A/C clutch hub with the Compressor Clutch Holding Tool. 2 Remove the bolt. 3. Remove the A/C clutch and the A/C clutch hub spacer. 1 Thread an 8 x 1.25 mm bolt into the A/C clutch hub spacer to force it from the compressor shaft. 2 Lift the A/C clutch and the A/C clutch hub spacer from the compressor shaft. 4. Remove the pulley snap ring. 5. Remove the A/C clutch pulley. 6. Remove the A/C clutch field coil. 1 Note the location of the A/C clutch field coil electrical connector. 2 Install the Field Coil Remover on the nose opening of the A/C compressor. 3 Install the Differential Bearing Cone Remover. 4 Remove the A/C clutch field coil. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Page 9078 CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. INSTALLATION 1. Clean the A/C clutch field coil and the pulley bearing mounting surfaces. 2. Install the A/C clutch field coil. 1 Place the A/C clutch field coil on the A/C compressor with the A/C clutch field coil electrical connector properly positioned. 2 Place the Field Coil Replacer on the A/C clutch field coil. 3 Place the Coil Replacer on the Field Coil Replacer. 4 Use the 2-Jaw Puller to install the A/C clutch field coil until bottomed completely against the A/C compressor. CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged. 3. Install the A/C clutch pulley. NOTE: The A/C clutch pulley is a tight fit on the A/C compressor head; it must be properly aligned during installation. 4. Install the pulley snap ring with the bevel side out. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > Page 9079 5. Place one nominal thickness A/C clutch hub spacer inside the clutch hub spline opening. 6. Install the A/C clutch. 7. Install the A/C clutch hub retaining bolt. 1 Hold the A/C clutch hub with the Compressor clutch Holding Tool. 2 Tighten the bolt. 8. Measure and adjust the clutch air gap by removing or adding the A/C clutch hub spacer. 9. Install the A/C compressor. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Specifications Compressor Clutch Hub: Specifications Compressor Clutch Hub Bolt ........................................................................................................................................................ 11-14 N.m (98-123 Lb-In) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair Compressor Shaft Seal: Service and Repair SPECIAL TOOL(S) REMOVAL 1. Remove the A/C clutch from the A/C compressor. 2. Remove the shaft seal felt from the nose of the A/C compressor with the O-ring Remover. 3. Clean the compressor nose area. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair > Page 9086 4. Insert the tip of the Snap Ring Remover into one of the snap ring eyes. 5. Rotate the Snap Ring Remover to position the tool tip and the snap ring eye closest to the A/C compressor shaft. 6. Pull the Snap Ring Remover up quickly while keeping the tool shaft against the side of the nose opening and remove the snap ring. 7. Engage the Compressor Seal Remover into the inside diameter of the shaft seal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair > Page 9087 8. Turn the tool handle clockwise to expand the tool tip inside of the shaft seal. 9. Pull the seal from the A/C compressor. INSTALLATION 1. Clean the A/C compressor nose area. CAUTION: Do not allow dirt or other foreign materials to enter the A/C compressor. 2. Place the shaft seal on the Seal Protector. Lubricate the shaft seal and the Seal Protector with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. 3. Position the shaft seal and the Seal Protector over the A/C compressor shaft. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair > Page 9088 4. Push the shaft seal onto the A/C compressor shaft with the Shaft Seal Installer until seated. 5. Install the shaft seal snap ring. 6. Perform the A/C compressor external leak test. See: Testing and Inspection 7. Install the shaft seal felt. 8. Install the A/C clutch. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 9092 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 9093 Compressor Clutch Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations > Page 9094 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications Compressor Fitting HVAC: Specifications Manifold Tube Bolt ............................................................................................................................... .......................................... 18-24 N.m (14-18 Lb-Ft) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications > Page 9098 Compressor Fitting HVAC: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Recover the refrigerant. See: Service and Repair/Refrigerant Recovery 3. Remove the manifold and tube assembly. 1 Remove the bolt. 2 Remove the manifold and tube assembly. 4. Disconnect the A/C pressure cut-off switch electrical connector. 5. Disconnect the manifold and tube fitting at the suction accumulator/drier. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications > Page 9099 6. Disconnect the condenser core fitting. NOTE: Use a backup wrench to hold the line during disconnection to prevent damage to the line. 7. Remove the nut. 8. Remove the A/C pressure cut-off switch. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information > Specifications > Page 9100 1. Follow the removal procedure in reverse order. - Lubricate the O-ring seals with Motorcraft YN-1c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. - Apply Pipe Sealant with Teflon (R) D8AZ-19554-A or equivalent meeting Ford specifications WSK-M2G350-A2 and ESR-M18P7-A to the threads of the A/C manifold retaining bolt. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications Condenser HVAC: Specifications A/C Condenser Bracket Bolts ..................................................................................................................................................... 7.6-10.4 N.m (68-92 Lb-In) A/C Condenser Lower Line Fitting ................................................................................................................................................. 20-27 N.m (15-19 Lb-Ft) A/C Condenser Upper Line Fitting ................................................................................................................................................. 22-29 N.m (17-21 Lb-Ft) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 9104 Condenser HVAC: Description and Operation NOTE: Replacement of the suction accumulator/drier is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator/drier. The A/C condenser core has the following characteristics: - It is an aluminum fin and tube design heat exchanger located in front of the vehicle radiator. - It cools compressed refrigerant gas by allowing air to pass over fins and tubes to extract heat and by condensing gas to liquid refrigerant as it is cooled. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 9105 Condenser HVAC: Testing and Inspection ON-VEHICLE LEAK TEST 1. Discharge and recover the refrigerant. See: Service and Repair/Refrigerant Recovery 2. Disconnect the suspect A/C evaporator core or A/C condenser core from the A/C system. NOTE: DO NOT leak test an A/C evaporator core with the suction accumulator/drier attached to the core tubes. 3. Clean the spring lock couplings. 4. Connect the appropriate test fittings from the R-12/R-134a Air Conditioning Test Fitting Set to the evaporator or condenser tube connections. 5. Connect the red and blue hoses from the R-134a Manifold Gauge Set to the test fittings on the A/C evaporator core or A/C condenser core. Connect the yellow hose to a known good vacuum pump. NOTE: The automatic shut-off valves on some gauge set hoses do not open when connected to the test fittings. If available, use hoses without shut-off valves. If hoses with shut-off valves are used, make sure the valve opens when attached to the test fittings or install an adapter which will activate the valve. The test is not valid if the shut-off valve does not open. 6. Open both gauge set valves and start the vacuum pump. Allow the vacuum pump to operate for a minimum of 45 minutes after the gauge set low pressure gauge indicates 101 kPa (30 in-Hg). The 45 minute evacuation is necessary to remove any refrigerant from oil left in the A/C evaporator core or A/C condenser core. If the refrigerant is not completely removed from the oil, outgassing will degrade the vacuum and appear as a refrigerant leak. 7. If the low pressure gauge reading will not drop to 101 kpa (30 in-Hg) when the valves on the gauge and manifold set are open and the vacuum pump is operating, close the gauge set valves and observe the low pressure gauge. If the pressure rises rapidly to zero, a large leak is indicated. Recheck the test fitting connections and gauge set connections before replacing the A/C evaporator core or A/C condenser core. 8. After evacuating for 45 minutes, close the gauge set valves and stop the vacuum pump. Observe the low pressure gauge; it should remain at the 101 kPa (30 in-Hg) mark. If the low pressure gauge reading rises 34 or more kPa (10 or more in-Hg) of vacuum from the 101 kPa (30 in-Hg) position in 10 minutes, a leak is indicated. - If a very small leak is suspected, wait 30 minutes and observe the vacuum gauge. - If a small amount of vacuum is lost, operate the vacuum pump with gauge valves open for an additional 30 minutes to remove any remaining refrigerant from the oil in the A/C evaporator core or A/C condenser core. Then recheck for loss of vacuum. - If a very small leak is suspected, allow the system to set overnight with vacuum applied and check for vacuum loss. 9. If the A/C evaporator core or A/C condenser core does leak, as verified by the above procedure, install a new A/C evaporator core or A/C condenser core. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 9106 Condenser HVAC: Service and Repair REMOVAL CAUTION: To prevent refrigerant system contamination whenever an A/C condenser core is replaced, also replace the suction accumulator/drier. If an A/C condenser core leak is suspected, the A/C condenser core must he leak tested before it is removed from the vehicle. 1. Disconnect the battery. 2. Recover the refrigerant. See: Service and Repair/Refrigerant Recovery 3. Remove the radiator. 4. Disconnect the A/C condenser core inlet and outlet hoses. NOTE: Use a backup wrench to hold the line during disconnection to prevent damage to the line. 5. Remove the A/C condenser core. 1 Remove the bolts. 2 Remove the A/C condenser brackets. 3 Remove the A/C condenser core. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications > Page 9107 1. Follow the removal procedure in reverse order. - Service the replacement A/C condenser core with the correct amount of Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. - Lubricate the O-ring seals with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams Control Assembly: Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Page 9111 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Page 9112 Control Assembly: Description and Operation The manual climate control system heats or cools the vehicle interior depending on the function selector position and the temperature selected. Function selector position determines heating or cooling and air distribution. The temperature blend control setting determines air temperature. The manual climate control components are used to: - select air inlet source (outside or recirculated). - select blower motor speed. - select discharge air temperature (temperature blend). - select discharge air location (defrost, panel, floor). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Diagrams > Page 9113 - select A/C compressor clutch operation. Control System Inputs The climate control assembly has three system controls: The A/C heater function selector switch combines a vacuum selector valve with two electrical switches to supply battery positive voltage (B+) to the A/C clutch circuit and the blower motor control circuit. - The temperature selection is accomplished with a potentiometer connected to the electric blend door actuator that controls positioning of the temperature blend door. Movement of the control knob from COOL (blue) to WARM (red) causes a corresponding movement on the air temperature control door and determines the temperature that the system will maintain. - The blower motor switch controls blower motor speed by adding or bypassing resistors in the heater blower motor switch resistor. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Climate Control Switches Control Assembly: Service and Repair Climate Control Switches REMOVAL 1. Remove the control assembly. 2. Remove the function selector. 1 Depress the snap tabs. 2 Remove the function selector. NOTE: The knob will drop off as the function selector is removed. 3. Remove the blower motor switch. 1 Remove the screw. 2 Rotate and pull the temperature blend control switch. NOTE: The knob will drop off as the temperature blend control switch is removed. 4. Remove the blower motor switch. 1 Depress the snap tabs. 2 Remove the blower motor switch. NOTE: The knob will drop off as the blower motor switch is removed. INSTALLATION 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Climate Control Switches > Page 9116 Control Assembly: Service and Repair Control Assembly, HVAC REMOVAL 1. Disconnect the battery. 2. Remove the instrument panel relay cover. 3. Disconnect the two passenger air bag defeat switch electrical connectors. 4. Remove the center instrument panel finish panel. - Carefully pry to release four clips. 5. If equipped, disconnect the 4WD control switch connector. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service and Repair > Climate Control Switches > Page 9117 6. Remove the climate control assembly. 1 Remove the screws. 2 Pull out the climate control assembly. 7. Disconnect the climate control assembly. 1 Disconnect the electrical connectors. 2 Disconnect the vacuum line connector. INSTALLATION 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Specifications Coupler HVAC: Specifications Peanut Fitting Nut ................................................................................................................................ ........................................................ 8 N.m (71 Lb-In) Manifold Tube Peanut Fitting .......................... .............................................................................................................................................. 8 N.m (6 Lb-Ft) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Specifications > Page 9121 Coupler HVAC: Description and Operation Spring Lock Coupling The spring lock coupling is a refrigerant line coupling held together by a garter spring inside a circular cage. - When the coupling is connected together, the flared end of the female fitting slips behind the garter spring inside the cage of the male fitting. - The garter spring and cage then prevent the flared end of the female fitting from pulling out of the cage. - Three O-ring seals are used to seal between the two halves of the A/C condenser core couplings, all other couplings have two O-ring seals. - These O-ring seals are green in color and are made of special material. - Use only the green O-ring seals listed in the Ford Master Parts Catalog for the spring lock coupling. - A plastic indicator ring is used on the spring lock couplings of the A/C evaporator core to indicate, during vehicle assembly, that the coupling is connected. Once the coupling is connected, the indicator ring is no longer necessary but will remain captive by the coupling near the cage opening. - The indicator ring may also be used during service operations to indicate connection of the coupling. - An A/C tube lock coupling clip may be used to secure the coupling but is not required. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Peanut Fitting Coupler HVAC: Service and Repair Peanut Fitting DISCONNECT 1. Remove the nut from the peanut fitting. CAUTION: Support the female fitting with a wrench to prevent the tubes from twisting. 2. Pull the peanut fitting apart. 3. Remove the O-ring seal with a non-metallic tool. CAUTION: Do not use metal tools to remove the O-ring seal. They can cause axial scratches across the O-ring groove resulting in refrigerant leaks. CONNECT 1. Clean all dirt or foreign material from the fittings. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Peanut Fitting > Page 9124 2. Install the O-ring seal. - Lubricate the O-ring seal with Motorcraft YN-12c Refrigerant Oil or equivalent meeting Ford specification WSH-M1C231-B. CAUTION: Use only new green O-rings. The use of any O-ring seals other than specified may result in intermittent leakage during vehicle operation. 3. Lubricate the inside of the fittings with Motorcraft YN-12c Refrigerant Oil or equivalent meeting Ford specification WSH-M1C231-B. 4. Assemble the male and female fittings together. NOTE: When properly assembled the male and female fittings should be flush. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Peanut Fitting > Page 9125 Coupler HVAC: Service and Repair Spring Lock Coupling SPECIAL TOOL(S) DISCONNECT 1. Remove the A/C tube lock coupling Clip. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Peanut Fitting > Page 9126 2. Fit the spring lock coupling disconnect tool to the spring lock coupling. 3. Push the tool into the cage opening to release the female fitting from the A/C tube lock coupling spring. 4. Pull the spring lock coupling fittings apart. 5. Remove the O-ring seals with a non-metallic tool. CAUTION: Do not use metal tools to remove the O-ring tools. They can cause axial scratches across the O-ring grooves resulting in refrigerant leaks. 6. Remove the A/C tube lock coupling spring with a small hooked wire. CAUTION: Do not use a screw driver or similar tool to remove the A/C tube lock coupling spring; this can cause axial scratches across the O-ring grooves resulting in refrigerant leaks. CLEANING Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Peanut Fitting > Page 9127 1. Fabricate a cleaning tool from a 1/8 inch diameter brazing rod. 2. Cut an abrasive pad from maroon colored 3M Scotch Brite (R) with the dimensions corresponding to the coupling size. Coupling Size Pad Size 3/8 inch 25 x 50 mm (1 x 2 inch) 1/2 inch 25 x 50 mm (1 x 2 inch) 5/8 inch 25 x 76 mm (1 x 3 inch) 3/4 inch 25 x 102 mm (1 x 4 inch) 3. Assemble the pad to the tool. 4. Coat the abrasive pad with Motorcraft YN-12b Refrigerant Oil or equivalent meeting Ford specification WSH-M1C231-B. 5. Roll the pad on the tool and install it in a variable speed drill motor. 6. Polish for 1 minute at moderate speed (less than 1500 rpm) or until the surface is clean and free of scratches or debris. CAUTION: Maintain low speed drill rotation when inserting or removing the cleaning tool to prevent axial scratches which may cause future leaks. 7. Clean the fitting with a lint-free cloth. 8. Inspect the surface for grooves or scratches. If grooves and scratches are still present, replace the component. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Peanut Fitting > Page 9128 9. Clean the O-ring grooves with a 300 mm (12 inch) length of natural fiber string. - Loop the string around the grooves and pull the string back and forth. 10. Remove any debris from the grooves with a lint-free cloth. CONNECT 1. Install the A/C tube lock coupling spring. 2. Lubricate the inside of the coupling with Motorcraft YN-12c Refrigerant Oil or equivalent meeting Ford specification WSH-M1C231-B. 3. Install the O-ring seals. - Lubricate the O-ring seals with Motorcraft YN-12c Refrigerant Oil or equivalent meeting Ford specification WSH-M1C231-B. CAUTION: Use only new green O-rings. The use of any O-ring seals other than specified may result in intermittent leakage during vehicle operation. 4. Connect the spring lock coupling fittings with a twisting motion until the A/C tube lock coupling spring snaps over the flared end of the female fitting. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair > Peanut Fitting > Page 9129 5. Install the A/C tube lock coupling clip. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair Evaporator Case: Service and Repair REMOVAL 1. Remove the battery and the battery tray brackets. 2. Recover the refrigerant. See: Service and Repair/Refrigerant Recovery 3. Drain the cooling system. See: Engine, Cooling and Exhaust/Cooling System/Service and Repair 4. Remove the instrument panel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 5. Disconnect the heater core hose couplings. See: Heater Hose/Service and Repair 6. Disconnect the refrigerant line spring lock couplings from the A/C evaporator core. See: Coupler HVAC/Service and Repair 7. Remove the plenum chamber nuts. 8. Disconnect the A/C vacuum hose from the A/C vacuum check valve. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair > Page 9133 9. Remove the plenum chamber nuts. 10. Remove the plenum chamber. INSTALLATION 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation Evaporator Core: Description and Operation NOTE: Replacement of the suction accumulator/drier is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator/drier. The A/C evaporator core is the plate/fin type with a unique refrigerant flow path. - A mixture of refrigerant and oil enters the bottom of the A/C evaporator core through the A/C evaporator core inlet tube and is routed so it flows through the partitioned first three plate/fin sections. - The next four plate/fin sections are partitioned to force the refrigerant to flow toward the other end of the A/C evaporator core. - Refrigerant then continues over to the remaining five plate/fin sections and then moves out of the A/C evaporator core through the A/C evaporator core outlet tube. - This S-pass flow pattern accelerates the flow of the refrigerant and the oil through the A/C evaporator core. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Page 9137 Evaporator Core: Testing and Inspection ON-VEHICLE LEAK TEST 1. Discharge and recover the refrigerant. See: Service and Repair/Refrigerant Recovery 2. Disconnect the suspect A/C evaporator core or A/C condenser core from the A/C system. NOTE: DO NOT leak test an A/C evaporator core with the suction accumulator/drier attached to the core tubes. 3. Clean the spring lock couplings. 4. Connect the appropriate test fittings from the R-12/R-134a Air Conditioning Test Fitting Set to the evaporator or condenser tube connections. 5. Connect the red and blue hoses from the R-134a Manifold Gauge Set to the test fittings on the A/C evaporator core or A/C condenser core. Connect the yellow hose to a known good vacuum pump. NOTE: The automatic shut-off valves on some gauge set hoses do not open when connected to the test fittings. If available, use hoses without shut-off valves. If hoses with shut-off valves are used, make sure the valve opens when attached to the test fittings or install an adapter which will activate the valve. The test is not valid if the shut-off valve does not open. 6. Open both gauge set valves and start the vacuum pump. Allow the vacuum pump to operate for a minimum of 45 minutes after the gauge set low pressure gauge indicates 101 kPa (30 in-Hg). The 45 minute evacuation is necessary to remove any refrigerant from oil left in the A/C evaporator core or A/C condenser core. If the refrigerant is not completely removed from the oil, outgassing will degrade the vacuum and appear as a refrigerant leak. 7. If the low pressure gauge reading will not drop to 101 kpa (30 in-Hg) when the valves on the gauge and manifold set are open and the vacuum pump is operating, close the gauge set valves and observe the low pressure gauge. If the pressure rises rapidly to zero, a large leak is indicated. Recheck the test fitting connections and gauge set connections before replacing the A/C evaporator core or A/C condenser core. 8. After evacuating for 45 minutes, close the gauge set valves and stop the vacuum pump. Observe the low pressure gauge; it should remain at the 101 kPa (30 in-Hg) mark. If the low pressure gauge reading rises 34 or more kPa (10 or more in-Hg) of vacuum from the 101 kPa (30 in-Hg) position in 10 minutes, a leak is indicated. - If a very small leak is suspected, wait 30 minutes and observe the vacuum gauge. - If a small amount of vacuum is lost, operate the vacuum pump with gauge valves open for an additional 30 minutes to remove any remaining refrigerant from the oil in the A/C evaporator core or A/C condenser core. Then recheck for loss of vacuum. - If a very small leak is suspected, allow the system to set overnight with vacuum applied and check for vacuum loss. 9. If the A/C evaporator core or A/C condenser core does leak, as verified by the above procedure, install a new A/C evaporator core or A/C condenser core. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Page 9138 Evaporator Core: Service and Repair REMOVAL CAUTION: To prevent refrigerant system contamination, if you are replacing the A/C evaporator core you must also replace the suction accumulator/drier. See: Accumulator HVAC/Service and Repair NOTE: If an A/C evaporator core leak is suspected, the A/C evaporator core must be leak tested before it is removed from the vehicle. 1. Recover the refrigerant. 2. Drain the radiator. 3. Remove the instrument panel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 4. Disconnect the heater water hoses at the heater core. 5. Disconnect the refrigerant line spring lock couplings form the A/C evaporator core. See: Coupler HVAC/Service and Repair 6. Remove the RH A/C plenum demister adapter. 1. Remove the screw. 2. Remove the RH A/C plenum demister adapter. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Page 9139 7. Remove the heater core outlet bracket. 1. Remove the screws. 2. Remove the bracket. 8. Remove the plenum assembly top. 1. Remove the 14 screws. 2. Remove the plenum assembly top. 9. Remove the A/C evaporator core from the plenum assembly. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Description and Operation > Page 9140 1. Follow the removal procedure in reverse order. - Service the replacement A/C evaporator core with the correct amount of Motorcraft YN-12c refrigerant oil meeting Ford specification WSH-M1C231-B. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Description and Operation Expansion Block/Orifice Tube: Description and Operation NOTE: Replacement of the suction accumulator/drier is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator/drier. A/C Evaporator Core Orifice The A/C evaporator core orifice has the following characteristics: - Is located in the A/C evaporator core inlet tube. - Has filter screens located on the inlet and outlet ends of the tube body. - The inlet filter screen acts as a strainer for the liquid refrigerant flowing through the A/C evaporator core orifice. - O-rings on the A/C evaporator core orifice prevent the high pressure liquid refrigerant from bypassing the A/C evaporator core orifice. - Adjustment or service cannot be made to the A/C evaporator core orifice assembly. It must be replaced as a unit. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Description and Operation > Page 9144 Expansion Block/Orifice Tube: Service and Repair SPECIAL TOOL(S) REMOVAL 1. Remove the condenser to the condenser to evaporator line. - For a fixed orifice tube, perform Steps 2 and 3. - For a broken orifice tube, perform Steps 4 and 5. 2. Engage (A) Fixed Orifice Tube Tool to the A/C evaporator core orifice. 3. Hold the tool T-handle stationary and rotate the tool body to remove the A/C evaporator core orifice. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Description and Operation > Page 9145 4. To remove a broken A/C evaporator core orifice; screw the end of the Broken Orifice Extractor into the broken A/C evaporator core orifice. 5. Hold the tool T-handle stationary and rotate the tool body to remove the broken A/C evaporator core orifice. INSTALLATION 1. Lubricate and install the O-ring seals on the A/C evaporator core orifice. - Use Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. 2. Place the A/C evaporator core orifice into the Fixed Orifice Tube Tool. 3. Insert the A/C evaporator core orifice into the condenser to evaporator line until seated. 4. Remove the Fixed Orifice Tube Tool. 5. Install the condenser to evaporator line. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 9154 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 9155 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Core: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 9161 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 9162 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 9163 Heater Core: Specifications Heater Core Bracket Screws ......................................................................................................................................................... 1.5-2.5 N.m (13-22 Lb-In) Heater Core Outlet Bracket Screws ............................................................................................................................................... 1.5-2.5 N.m (13-22 Lb-In) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 9164 Heater Core: Description and Operation The heater core consists of fins and tubes arranged to extract heat from the engine coolant and transfer it to air passing through the heater core. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 9165 Heater Core: Testing and Inspection HEATER CORE WARNING: CARBON MONOXIDE IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS NECESSARY TO OPERATE THE ENGINE WITH THE VEHICLE IN A CLOSED AREA SUCH AS A GARAGE, ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES OUTSIDE THE CLOSED AREA. 1. Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A coolant leak in the heater water hose could follow the heater core tube to the heater core and appear as a leak in the heater core. NOTE: Testing of returned heater cores reveals that a large percentage of heater cores are good and did not require replacement. If a heater core leak is suspected, the heater core must he tested by following the plugged heater core component test before the heater core pressure test. Perform a system inspection by checking the heater system thoroughly. 2. Check the integrity of the heater water hose clamps. NOTE: Spring-type clamps are installed as original equipment. Installation and overtightening of non-specification clamps can cause leakage at the heater water hose connection and damage the heater core. HEATER CORE - PLUGGED WARNING: THE HEATER CORE INLET HOSE WILL BECOME TOO HOT TO HANDLE IF THE SYSTEM IS WORKING CORRECTLY. 1. Check to see that the engine coolant is at the proper level. 2. Start the engine and turn on the heater. 3. When the engine coolant reaches operating temperature, feel the heater core outlet hose to see if it is hot. If it is not hot: the heater core may have an air pocket - the heater core may be plugged, or - the thermostat is not working properly. PRESSURE TEST Use the Radiator/Heater Core Pressure Tester to perform the pressure test. 1. Drain the coolant from the cooling system. NOTE: Due to space limitations, a bench test may be necessary for pressure testing. 2. Disconnect the heater water hoses from the heater core. 3. Install a short piece of heater water hose, approximately 101 mm (4 inches) long on each heater core tube. 4. Fill the heater core and heater water hoses with water and install Plug BT-7422-B and adapter BT-7422-A from the Radiator/Heater Core Pressure Tester in the heater water hose ends. Secure the heater water hoses, plug and adapter with hose clamps. 5. Attach the pump and gauge assembly from the Radiator/Heater Core Pressure Tester to the adapter. 6. Close the bleed valve at the base of the gauge. Pump 241 kpa (35 psi) of air pressure into the heater core. 7. Observe the pressure gauge for a minimum of three minutes. 8. If the pressure drops, check the heater water hose connections to the core tubes for leaks. If the heater water hoses do not leak, remove the heater core from the vehicle and perform the bench test. BENCH TEST 1. Remove the heater core from the vehicle. 2. Drain all of the coolant from the heater core. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 9166 3. Connect the 101 mm (4 inch) test heater water hoses with plug and adapter to the core tubes. Then connect the Radiator/Heater Core Pressure Tester to the adapter. 4. Apply 241 kPa (35 psi) of air pressure to the heater core. Submerge the heater core in water. 5. If a leak is observed, replace the heater core. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 9167 Heater Core: Service and Repair REMOVAL NOTE: If a heater core leak is suspected, the heater core must be leak-tested before it is removed from the vehicle. 1. Disconnect the battery. 2. Drain the cooling system. 3. Remove the instrument panel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 4. Compress the holding tabs and disconnect the heater water hoses at the heater core. See: Heater Hose/Service and Repair 5. Remove the A/C plenum demister adapter. 1 Remove the screw. 2 Remove the A/C plenum demister adapter. 6. Disconnect the vacuum line. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 9168 7. Remove the heater core bracket. 1 Remove the screws. 2 Remove the bracket. 8. Remove the plenum chamber top. 1 Remove the 13 screws. 2 Remove the plenum chamber top. 9. Remove the blend door assembly from the case. 10. Remove the heater core. INSTALLATION 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Specifications Heater Core Case: Specifications Plenum Top Screws ............................................................................................................................ ........................................... 1.5-2.5 N.m (13-22 Lb-In) Plenum Assembly Top Screws ...................................................................................................................................................... 1.5-2.5 N.m (13-22 Lb-In) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Specifications > Page 9172 Heater Core Case: Service and Repair REMOVAL 1. Remove the battery and the battery tray brackets. 2. Recover the refrigerant. See: Service and Repair/Refrigerant Recovery 3. Drain the cooling system. See: Engine, Cooling and Exhaust/Cooling System/Service and Repair 4. Remove the instrument panel. See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair 5. Disconnect the heater core hose couplings. See: Heater Hose/Service and Repair 6. Disconnect the refrigerant line spring lock couplings from the A/C evaporator core. See: Coupler HVAC/Service and Repair 7. Remove the plenum chamber nuts. 8. Disconnect the A/C vacuum hose from the A/C vacuum check valve. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Specifications > Page 9173 9. Remove the plenum chamber nuts. 10. Remove the plenum chamber. INSTALLATION 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 9182 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 9183 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage TSB 06-21-19 10/30/06 HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY) FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus 2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250 Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome Chassis, F-Super Duty, Ranger 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004 F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750 LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner 2006-2007 Mariner Hybrid This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure. ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality coolant. However, electrolysis should also be checked, especially when repeat repairs have occurred. ACTION If the heater core is leaking, review the location of the leakage and check the condition of the coolant. SERVICE PROCEDURE 1. Review the location of the leakage and check the condition of the coolant: a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely due to due to high flow rate - replace the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 9189 heater core and install a restrictor in the heater hose closest to the engine block, reference Workshop Manual, Section 412. b. If leaks are found in the body of the heater core itself, and does not appear to be the result of physical damage like contact or puncture, check the coolant for possible electrolysis. Testing For Electrolysis Check for voltage in the cooling system by touching the negative contact of a voltmeter to the battery ground or a known good ground and suspend the positive lead in the coolant, making sure it is in contact with the coolant but not touching any metal part of the radiator or cooling system. Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the engine block before addition to or replacement of. To keep more coolant from exiting the heater core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the original coolant with new coolant during testing if possible. 1. Determine whether coolant condition is acceptable. a. Remove both cables from the battery and ensure they do not contact each other or the vehicle. b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant. NOTE POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING. c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect battery cables and proceed to Step 2. d. If greater than 0.4 V, flush cooling system thoroughly. e. Recheck voltage less than or equal to 0.4 V. f. Reconnect battery cables. g. Refill the system with appropriate Motorcraft® engine coolant. 2. Check for loose or missing grounds at static conditions. a. Turn off all accessories. Turn ignition on but do not start engine. b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. c. Voltage less than or equal to 0.4 V on all grounds OK. d. Any one greater than 0.4 V, check and clean ground cable connections. e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper wire to ground. f. Plug in engine block heater, if equipped, and test. g. Recheck voltage less than or equal to 0.4 V. h. Unplug engine block heater, if equipped. 3. Check for loose, missing, or inadequate grounds. a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. b. Crank engine but do not start. c. Monitor voltage while cranking. less than or equal to 0.4 V OK d. If greater than 0.4 V, ground or repair starter. e. Start engine and run at about 2000 rpm. f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell phone, etc. g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 9190 h. Voltage less than or equal to 0.4 V OK i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair ground to the accessory just identified. j. Recheck voltage less than or equal to 0.4 V k. Turn the DVOM to AC volts. l. Check for ANY AC voltage greater than 0.4. m. If any AC voltage is present then try turning off each accessory one at a time including blower motor and any fan motors. n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it up then retest. o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install heavier gauge ground strap(s) and recheck. NOTE If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor voltage when they are on and when off. CAUTION DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE GROUND PATH. 4. Refill the engine cooling system, reference Workshop Manual, Section 303-03. NOTE IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT PROCEDURE IF REQUIRED. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 18476 42 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service Bulletins > Page 9191 Heater Hose: Specifications Hose Clamp ......................................................................................................................................... .......................................... 1.6-2.2 N.m (17-22 Lb-In) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Hose Couplings Heater Hose: Service and Repair Heater Hose Couplings Heater Hose Disconnect Tool SPECIAL TOOL(S) DISCONNECT 1. Depressurize the engine cooling system. WARNING: THE ENGINE MUST BE OFF, FULLY COOL AND THE COOLING SYSTEM FULLY DEPRESSURIZED BEFORE ATTEMPTING TO DISCONNECT ANY HEATER WATER HOSES. FAILURE TO COMPLY WITH THIS WARNING CAN RESULT IN SERIOUS INJURY OR BURNS FROM HOT LIQUID ESCAPING OUT OF THE ENGINE COOLING SYSTEM. 2. Push the heater water hose toward the tube to fully expose the locking tabs. 3. Push the Heater Hose Disconnect Tool over the coupling retainer windows to compress the retainer locking tabs. NOTE: When compressing the white coupling retainer, the Heater Hose Disconnect Tool must be perpendicular to and on the highest point of the coupling. 4. Pull the heater water hose away from the heater core tube. NOTE: A slight twisting motion while pulling on the heater water hose may be necessary to assist in the removal. 5. Plug the heater water hose. 6. Remove the white coupling retainer from the tube. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Hose Couplings > Page 9194 7. Spread the retainer tabs apart and slide the retainer off the tube. 8. Discard the retainer. CONNECT 1. Clean the tubes and lubricate with Ford Rubber Suspension Insulator Lube E25Y-19553-A or equivalent meeting Ford specification ESF-M99B112-A. 2. Install a new coupling retainer, spacer, and lubricated O-rings into the quick disconnect coupling housing. 3. Push the heater water hose with a quick disconnect coupling onto the tube. 4. Make sure the coupling is fully engaged by lightly pulling on the heater water hose. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Hose Couplings > Page 9195 Heater Hose: Service and Repair Removal and Installation REMOVAL 1. Drain the cooling system. 2. Disconnect the heater outlet hose at the engine. 3. Disconnect the heater inlet hose at the engine. 1 Loosen the hose clamp. 2 Disconnect the heater inlet hose. 4. Compress the holding tabs and disconnect the heater water hoses at the heater core. INSTALLATION 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Specifications > A/C High Pressure Safety Valve High Pressure Safety Valve HVAC: Specifications A/C High Pressure Safety Valve A/C Compressor Pressure Relief Valve ..................................................................................................................................... Opens at 3103 kPa (450 psi) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Specifications > A/C High Pressure Safety Valve > Page 9200 High Pressure Safety Valve HVAC: Specifications Compressor Relief Valve A/C Compressor Pressure Relief Valve ..................................................................................................................................... Opens at 3103 kPa (450 psi) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Description and Operation > A/C High Pressure Safety Valve High Pressure Safety Valve HVAC: Description and Operation A/C High Pressure Safety Valve An A/C compressor pressure relief valve is incorporated in the compressor A/C manifold and tube to: - relieve unusually high refrigerant system discharge pressure buildups, (3,103 kPa and above). - prevent damage to the A/C compressor and other system components. - avoid total refrigerant loss by closing after the excessive pressure has been relieved. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Description and Operation > A/C High Pressure Safety Valve > Page 9203 High Pressure Safety Valve HVAC: Description and Operation Compressor Relief Valve An A/C compressor pressure relief valve is incorporated in the compressor A/C manifold and tube to: - relieve unusually high refrigerant system discharge pressure buildups, (3,103 kPa and above). - prevent damage to the A/C compressor and other system components. - avoid total refrigerant loss by closing after the excessive pressure has been relieved. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Service and Repair > A/C High Pressure Safety Valve High Pressure Safety Valve HVAC: Service and Repair A/C High Pressure Safety Valve REMOVAL 1. Recover the refrigerant. See: Service and Repair/Refrigerant Recovery 2. Raise the vehicle on a hoist. 3. Remove the A/C compressor pressure relief valve. INSTALLATION 1. Follow the removal procedure in reverse order. - Lubricate the O-ring seal with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Service and Repair > A/C High Pressure Safety Valve > Page 9206 High Pressure Safety Valve HVAC: Service and Repair Compressor Relief Valve REMOVAL 1. Recover the refrigerant. See: Service and Repair/Refrigerant Recovery 2. Raise the vehicle on a hoist. 3. Remove the A/C compressor pressure relief valve. INSTALLATION 1. Follow the removal procedure in reverse order. - Lubricate the O-ring seal with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Specifications Hose/Line HVAC: Specifications Tube Bracket Nut ................................................................................................................................. ............................................. 10-14 N.m (8-10 Lb-Ft) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Specifications > Page 9210 Hose/Line HVAC: Description and Operation NOTE: Replacement of the suction accumulator/drier is not required when repairing the air conditioning system except when there is physical evidence of system contamination from a failed A/C compressor or damage to the suction accumulator/drier. The condenser to evaporator tube contains high pressure liquid refrigerant upstream of the A/C evaporator core orifice. The A/C manifold and tube is attached to the A/C compressor with the O-ring seals and has the following features: - The upstream side contains low pressure refrigerant gas. - The downstream side contains high pressure refrigerant gas. - An integral non-serviceable muffler and a serviceable high pressure A/C charge port valve are located on the downstream side. - The downstream side also contains a fitting used to mount the A/C pressure cut-off switch. A long-travel Scharder-type valve stem core is installed in the fitting so that the A/C pressure cut-off switch can be removed without discharging the A/C system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Specifications > Page 9211 Hose/Line HVAC: Service and Repair REMOVAL 1. Remove the battery and the battery tray. 2. Recover the refrigerant. See: Service and Repair/Refrigerant Recovery 3. Disconnect the condenser to evaporator line spring lock coupling from the A/C evaporator core. 4. Disconnect the condenser lower fitting. NOTE: Use a backup wrench to hold the line during disconnection to prevent damage to the condenser to evaporator line. 5. Remove the line bracket nut. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Specifications > Page 9212 6. Remove the suction accumulator/drier bracket clamp bolt. 7. Remove the condenser to evaporator line. INSTALLATION 1. Follow the removal procedure in reverse order. - Lubricate the O-ring seal with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and Operation Receiver Dryer: Description and Operation An A/C evaporator core orifice or O-ring seal is not considered a major component, but the A/C evaporator core orifice should be replaced whenever the A/C compressor is replaced for lack of performance. The suction accumulator/drier is mounted to the A/C accumulator bracket to the right of the vehicle centerline. The inlet tube of the suction accumulator/drier attaches directly to the A/C evaporator core outlet tube and the outlet tube of the suction accumulator/drier attaches to the A/C manifold and tube. After entering the inlet of the suction accumulator/drier, heavier oil-laden refrigerant contacts an internally mounted dome (which serves as an umbrella) and drips down onto the bottom of the canister. - A small diameter oil bleed hole, in the bottom of the vapor return tube, allows the accumulated heavier liquid refrigerant and oil mixture to re-enter the compressor suction line at a controlled rate. - As the heavier mixture passes through the small diameter liquid bleed hole, it has a second chance to vaporize and recirculate through the A/C compressor without causing compressor damage due to slugging. - A fine mesh screened filter fits tightly around the bottom of the vapor return tube to filter out refrigerant system contaminant particles. - A desiccant bag is mounted inside the canister to absorb any moisture which may be in the refrigerant system. - A fitting located on the top of the suction accumulator/drier is used to attach the A/C cycling switch. A long-travel Schrader-type valve stem core Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and Operation > Page 9216 is installed in the fitting so that the A/C cycling switch can be removed without discharging the A/C system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants Technical Service Bulletin # 99-19-6 Date: 990920 A/C - Identification of Non Approved Refrigerants Article No. 99-19-6 09/20/99 ^ AIR CONDITIONING - IDENTIFICATION OF NON-FORD APPROVED REFRIGERANTS ^ AIR CONDITIONING - PURGING AIR FROM SYSTEM FORD: 1985-1986 LTD 1985-1988 EXP 1985-1994 TEMPO 1985-1997 THUNDERBIRD 1985-2000 CROWN VICTORIA, ESCORT, MUSTANG 1986-2000 TAURUS 1988-1993 FESTIVA 1989-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2000 FOCUS 1985-1990 BRONCO II 1985-1996 BRONCO 1985-1997 F-250 HD, F-350 1985-2000 ECONOLINE, F-150, F-250 LD, RANGER 1986-1997 AEROSTAR 1988-1997 F SUPER DUTY 1991-2000 EXPLORER 1995-2000 WINDSTAR 1997-2000 EXPEDITION 1999-2000 SUPER DUTY F SERIES 1985-1991 CL-CLT-9000 SERIES 1985-1999 L SERIES 1985-2000 F & B SERIES 1986-1998 CARGO SERIES 1997-1998 AEROMAX, LOUISVILLE LINCOLN: 1985-1992 MARK VII 1985-2000 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000 LS 1998-2000 NAVIGATOR MERCURY: 1985-1986 MARQUIS 1985-1987 LYNX 1985-1994 TOPAZ 1985-1997 COUGAR 1985-2000 GRAND MARQUIS 1986-2000 SABLE 1987-1989 TRACER 1991-1994 CAPRI 1991-2000 TRACER 1995-2000 MYSTIQUE 1999-2000 COUGAR 1993-2000 VILLAGER 1997-2000 MOUNTAINEER MERKUR: 1985-1989 XR4TI 1988-1989 SCORPIO Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 9221 This TSB article is being republished in its entirety to add model year vehicles ISSUE A number of non-approved/alternate refrigerants have entered the marketplace and are being advertised as "drop-in replacements" for R-12 and R-134a. The use of non-approved refrigerants such as R-22, hydrocarbons, and other refrigerant blends could cause safety, durability, and performance concerns if they are installed in Ford A/C systems. Identification of the type of refrigerant contained in vehicle A/C systems, before servicing, is necessary to prevent dealer service equipment and refrigerant supplies from being contaminated with non-approved refrigerants. ACTION Refrigerant identification must be performed prior to recovering the refrigerant into a recovery machine to prevent cross-contamination of the recovery machine and other A/C systems being serviced with that recovery machine. Refer to the following text. OTHER APPLICABLE ARTICLES: 94-14-3, 95-18-4 SUPERSEDES: 98-12-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1993-2000 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles OPERATION DESCRIPTION TIME 991906A Test A/C System For 0.3 Hr. Contaminated Refrigerant DEALER CODING CONDITION BASIC PART NO. CODE R-12 49 OASIS CODES: 208000, 208999 A/C Refrigerant Analyzer Function Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 9222 Ford Motor Company has approved the Rotunda Deluxe A/C Refrigerant Analyzer (198-00003) for use on Ford and Lincoln-Mercury vehicles (Figure 1). The analyzer provides the technician with a quick and easy way to identify the type and percentage of refrigerant (R-134a, R-12, R-22, or flammable hydrocarbon). The analyzer can also provide the percentage of air in the A/C system and automatically purge air from the system. The A/C Refrigerant Analyzer is designed to identify vapor gas samples taken directly from automotive air conditioning systems or refrigerant storage cylinders. Refrigerant vapor passes through the multiple sensor Non-Dispersive Infra-Red (NDIR) sensing unit. The microprocessor calculates each refrigerant type and purity percentage which is displayed on the analyzer's Liquid Crystal Display (LCD). The analyzer identifies the purity percentage of R-134a, R-12, R-22, hydrocarbon; and air in the sample. If the purity percentage of the R-134a or R-12 is 98% or greater by weight, a green "PASS" Light Emitting Diode (LED) will light. If refrigerants R-134a or R-12 do not meet 98% purity levels, the red "FAIL" LED will light. Levels of R-22 and flammable hydrocarbons above 2% will light the red "FAIL" light. If a hydrocarbon is detected above 5%, both the "FAIL" light and "HYDROCARBON" light will illuminate and a horn will sound alerting the user of potential hazards. The percent of air contained in the sample will be displayed if the R-134a or R-12 content is 98% or above. The analyzer eliminates the effect of air Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 9223 when determining the refrigerant sample content because air is not considered a contaminant although air can affect A/C system performance. Air will automatically be purged until a pure refrigerant with a less than 2% by weight air measurement is reached. Recovery of Contaminated Refrigerant If contaminated refrigerant is detected, DO NOT recover the refrigerant into your R-134a or R-12 recovery/recycling equipment. Take the following actions: 1. Repeat the test to verify contaminated refrigerant is present. 2. Advise the customer of the contaminated A/C system and any additional cost to repair the system. The customer may wish to return to the service facility which performed the last A/C service. 3. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant. This equipment must only be used to recover contaminated refrigerant to prevent the spread to other vehicles. As an alternative, contact an A/C service facility in your area which has the proper equipment for refrigerant recovery. Repairing A Contaminated A/C System Once the contaminated refrigerant is removed from the system it will be necessary to repair the system. Ford recommends that you do the following to be sure a quality repair is made: 1. Determine the cause of the failure. 2. Determine which parts will need to be replaced. 3. Flush the heat exchangers to remove any oil that may be degraded due to the contaminated refrigerant. 4. Install a new suction/accumulator. 5. Properly oil match the system to verify that the correct amount of clean refrigerant oil is present in the system. 6. Evacuate the system for 45 minutes. 7. Recharge the system, verify proper operation, and leak test. Disposal of Contaminated Refrigerant Disposal of contaminated refrigerant is a new process to the automotive industry Listed below are companies that will assist with disposal of contaminated refrigerant. Ford Motor Company has not evaluated the processes of the listed refrigerant disposal companies and is not endorsing or promoting their companies Business transactions are between the dealership and disposal companies. Disposal costs will vary between $3.00 and $5.00 per pound, plus the cost of round trip cylinder shipping. ^ Omega Refrigerant Reclamation ^ 5263 North Fourth St. ^ Irwindale, CA 91706 ^ (310) 698-0991 FAX: (310) 696-7908 ^ Full Cycle Global ^ 2966 Wireton ^ Blue Island, IL 60406 ^ (708) 388-8551 FAX: (708) 399-6550 ^ U.S. Refrigerant Reclaim, Inc. ^ 12420 North Green River Road ^ Evansville, IN 47711 ^ (800) 207-5931 FAX: (812) 867-1463 ^ Full Cycle Global ^ 343 South Airline Highway Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 9224 ^ Gonzales, LA 70737 ^ (504) 644-5333 FAX: (504) 644-1609 ^ CFC Reclamation ^ 1321 Swift North ^ Kansas City, MO 64116 ^ (816) 471-2511 ^ Full Cycle Global ^ 550 James St. ^ Lakewood, NJ 08701 ^ (908) 370-3400 FAX: (908) 370-3088 ^ National Refrigerants, Inc. ^ 11401 Roosevelt Blvd. ^ Philadelphia, PA 19154 ^ (215) 698-6620 FAX: (215) 602-8205 ^ Gartech Refrigerant Reclamation ^ 2002 Platinum ^ Garland, TX 75042 ^ (214) 272-4070 FAX: (214) 272-6548 ^ Refrigerant Reclaim Services ^ 121 S. Norwood Dr. ^ Hurst, TX 76053-7807 ^ (817) 282-0022 FAX: (800) 831-6182 ^ Full Cycle Global ^ 2055 Silber, Suite 109 ^ Houston, TX 77055 ^ (713) 681-7370 FAX: (713) 681-9947 ^ Refrigerant Reclaim, Inc. ^ 122 Old Stage Coach Road ^ Dumfries, VA 22026 ^ (800) 238-5902 FAX: (703) 441-0393 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Refrigerant Capacity ............................................................................................................................ ......................................................... 0.94 kg (33 oz) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 9227 Refrigerant: Fluid Type Specifications Refrigerant............................................................................................................................................ ........................................................................R134a Ford Part Number ................................................................................................................................ ..................................................................... YN-19 Ford Specification ................................................................................................................................ ................................................... WSH-M17B19-A Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Refrigerant Capacity ............................................................................................................................ ............................................................ 266 ml (9 oz) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 9232 Refrigerant Oil: Fluid Type Specifications Refrigerant Oil...................................................................................................................................... ...Polyalkylene Glycol (PAG) Oil (R-134a Systems) Ford Part Number ........................................................................................................................................................... F7AZ-19589-AD (MC-YN-12C) Ford Specification ................................................................................................................................ .................................................. WSH-M1C231-B Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Mechanical Specifications Refrigerant Pressure Sensor / Switch: Mechanical Specifications A/C Cycling Switch .............................................................................................................................. ......................................... 1.4-3.8 N.m (12-33 Lb-In) Pressure Cut Off Switch ................................... .......................................................................................................................................... 10 N.m (89 Lb-In) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Mechanical Specifications > Page 9237 Refrigerant Pressure Sensor / Switch: Pressure, Vacuum and Temperature Specifications A/C Cycling Switch Close ................................................................................................................................................... ..................................... 324 kPa (47 psi) Maximum Open .................................................................. ....................................................................................................................... 152 kPa (22 psi) Minimum Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Cutoff Switch Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Cutoff Switch Typical Air Conditioning Pressure Sensor The A/C pressure cut-off switch is used to interrupt the A/C compressor operation in the event of high system discharge pressures. - The A/C pressure cut-off switch is mounted on a Schrader valve-type fitting on the high pressure side of the A/C manifold and tube. - A valve depressor, located inside the threaded end of the A/C pressure cut-off switch, presses on the Schrader valve stem. - This allows the A/C pressure cut-off switch to monitor the compressor discharge pressure. - When the compressor discharge pressure rises to approximately 2,999-3,276 kPa (435-475 psi), the switch contacts open, disengaging the A/C compressor. - When the pressure drops to approximately 1,585-2,000 kPa (230-290 psi), the contacts close to allow operation of the A/C compressor. - It is not necessary to discharge the refrigerant system to remove the A/C pressure cut-off switch. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Cutoff Switch > Page 9240 Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Switch A/C Cycling Switch The A/C cycling switch is mounted on a Schrader valve-type fitting on the top of the suction accumulator/drier. - A valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the Schrader valve stem. - This allows the suction pressure inside the suction accumulator/drier to control the operation of the A/C cycling switch. - The electrical switch contacts open when the suction pressure drops to 151-173 kPa (22-25 psi). - The contacts close when the suction pressure rises to 268-324 kPa (39-47 psi). - When the A/C cycling switch contacts close, the A/C clutch field coil is energized. - When the A/C cycling switch contacts open, the A/C clutch field coil is deenergized and compressor operation stops. - The A/C cycling switch will control the A/C evaporator core pressure at a point where the plate/fin surface temperature will be maintained slightly above freezing. - This prevents icing of the A/C evaporator core and blockage of airflow. - It is not necessary to discharge the refrigerant system to remove the A/C cycling switch. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch Refrigerant Pressure Sensor / Switch: Service and Repair A/C Cycling Switch REMOVAL 1. Disconnect the A/C cycling pressure switch electrical connector. 2. Remove the A/C cycling switch from the top of the suction accumulator/drier. INSTALLATION 1. Follow the removal procedure in reverse order. - Lubricate the O-ring with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch > Page 9243 Refrigerant Pressure Sensor / Switch: Service and Repair A/C Pressure Cut-Off Switch REMOVAL 1. Disconnect the A/C pressure cut-off switch electrical connector. 2. Remove the A/C pressure cut-off switch. INSTALLATION 1. Follow the removal procedure in reverse order. - Lubricate the O-ring seal with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component Information > Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 9251 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 9252 Compressor Clutch Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations > Page 9253 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Mechanical Specifications Refrigerant Pressure Sensor / Switch: Mechanical Specifications A/C Cycling Switch .............................................................................................................................. ......................................... 1.4-3.8 N.m (12-33 Lb-In) Pressure Cut Off Switch ................................... .......................................................................................................................................... 10 N.m (89 Lb-In) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Specifications > Mechanical Specifications > Page 9259 Refrigerant Pressure Sensor / Switch: Pressure, Vacuum and Temperature Specifications A/C Cycling Switch Close ................................................................................................................................................... ..................................... 324 kPa (47 psi) Maximum Open .................................................................. ....................................................................................................................... 152 kPa (22 psi) Minimum Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Cutoff Switch Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Cutoff Switch Typical Air Conditioning Pressure Sensor The A/C pressure cut-off switch is used to interrupt the A/C compressor operation in the event of high system discharge pressures. - The A/C pressure cut-off switch is mounted on a Schrader valve-type fitting on the high pressure side of the A/C manifold and tube. - A valve depressor, located inside the threaded end of the A/C pressure cut-off switch, presses on the Schrader valve stem. - This allows the A/C pressure cut-off switch to monitor the compressor discharge pressure. - When the compressor discharge pressure rises to approximately 2,999-3,276 kPa (435-475 psi), the switch contacts open, disengaging the A/C compressor. - When the pressure drops to approximately 1,585-2,000 kPa (230-290 psi), the contacts close to allow operation of the A/C compressor. - It is not necessary to discharge the refrigerant system to remove the A/C pressure cut-off switch. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Description and Operation > A/C Pressure Cutoff Switch > Page 9262 Refrigerant Pressure Sensor / Switch: Description and Operation A/C Pressure Switch A/C Cycling Switch The A/C cycling switch is mounted on a Schrader valve-type fitting on the top of the suction accumulator/drier. - A valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the Schrader valve stem. - This allows the suction pressure inside the suction accumulator/drier to control the operation of the A/C cycling switch. - The electrical switch contacts open when the suction pressure drops to 151-173 kPa (22-25 psi). - The contacts close when the suction pressure rises to 268-324 kPa (39-47 psi). - When the A/C cycling switch contacts close, the A/C clutch field coil is energized. - When the A/C cycling switch contacts open, the A/C clutch field coil is deenergized and compressor operation stops. - The A/C cycling switch will control the A/C evaporator core pressure at a point where the plate/fin surface temperature will be maintained slightly above freezing. - This prevents icing of the A/C evaporator core and blockage of airflow. - It is not necessary to discharge the refrigerant system to remove the A/C cycling switch. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch Refrigerant Pressure Sensor / Switch: Service and Repair A/C Cycling Switch REMOVAL 1. Disconnect the A/C cycling pressure switch electrical connector. 2. Remove the A/C cycling switch from the top of the suction accumulator/drier. INSTALLATION 1. Follow the removal procedure in reverse order. - Lubricate the O-ring with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Service and Repair > A/C Cycling Switch > Page 9265 Refrigerant Pressure Sensor / Switch: Service and Repair A/C Pressure Cut-Off Switch REMOVAL 1. Disconnect the A/C pressure cut-off switch electrical connector. 2. Remove the A/C pressure cut-off switch. INSTALLATION 1. Follow the removal procedure in reverse order. - Lubricate the O-ring seal with Motorcraft YN-12c refrigerant oil or equivalent meeting Ford specification WSH-M1C231-B. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Description and Operation Service Port HVAC: Description and Operation Service Gauge Port Valve The high pressure service gauge port valve is located on the A/C manifold and tube. The low pressure service gauge port valve is located on the suction accumulator/drier. The fitting is an integral part of the refrigeration line or component. - Special couplings are required for both the high side and the low side service gauge ports. - The Schrader-type valve core can be replaced if the seal leaks. - Always install the A/C charging valve cap on the service gauge port valves after repairing the refrigerant system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service and Repair Vacuum Harness HVAC: Service and Repair Vacuum Pump Kit SPECIAL TOOL(S) 1. Measure the length of the damaged area of the mini-tube vacuum hose. 2. Cut a piece of standard 1/8 inch inner diameter vacuum hose approximately 25 mm (1 inch) longer than the damaged area of the mini-tube vacuum hose. 3. Cut off the mini-tube vacuum hose on each side of the damaged area. 4. Dip the mini-tube hose ends in commercially available paint thinner containing Methyl Ethyl Ketone (MEK). This solvent will seal the mini-tube in the vacuum hose. WARNING: READ THE WARNING INFORMATION ON THE PRODUCT LABEL. 5. Insert the ends of the mini-tube vacuum hose approximately 9 mm (3/8 inch) into the ends of the standard 1/8 inch service vacuum hose section. 6. Shake the service joint after assembly to ensure the solvent is dispersed and the vacuum line is not plugged. 7. Test the system for a vacuum leak in the repair area. - Use the Vacuum Pump or equivalent. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Reservoir HVAC > Component Information > Service and Repair Vacuum Reservoir HVAC: Service and Repair REMOVAL 1. Remove the battery and battery tray bracket. 2. Disconnect the A/C vacuum tank hose from the A/C vacuum reservoir tank and bracket. 3. Remove the screw and the A/C vacuum reservoir tank and bracket. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When positioning the A/C vacuum reservoir tank, make sure that the bottom locator and two top tabs align with the battery tray. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. - To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming Deactivation Procedure 1. Disconnect the battery ground cable. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the driver air bag module from the vehicle. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set an air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. 4. Connect an air bag simulator to the vehicle harness at the top of the steering column. 5. Disconnect the passenger air bag module electrical connector. 6. Connect an air bag simulator to the vehicle harness. 7. Reconnect the battery ground cable. Reactivation Procedure 1. Disconnect the battery ground cable. WARNING: The air bag simulators must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the air bag simulator from the vehicle harness connector at the top of the steering column. 4. Install the driver air bag module. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. 5. Remove the air bag simulator from the vehicle harness connector at the passenger air bag module. 6. Connect the passenger air bag module electrical connector. 7. Reconnect the battery ground cable. 8. Prove out the system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 9282 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist should be completed following diagnosis or repair of any air bag system concern. 1. Is the connector at the base of the steering column connected? ................................................................................................................................ [ ] 2. Are the air bag modules connected? ............................................................................................... .......................................................................... [ ] 3. Is the Restraints Control Module (RCM) connected? ............................................................................................................................................... [ ] 4. Is the vehicle battery connected? .................................................................................................... .......................................................................... [ ] Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Specifications Air Bag: Specifications Driver Air Bag Module Screws ............................................................................................................. ..................................................... 11 Nm (98 Lb-In) Passenger Air Bag Module Screws ................... ............................................................................................................................................ 9 Nm (80 Lb-In) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Specifications > Page 9286 Air Bag: Description and Operation F-150, F-250 Air Bag Module - Driver The driver air bag module: is replaced as an assembly. - is mounted in the center of the steering wheel. Air Bag Module - Passenger The passenger air bag module: is replaced as an assembly. - is mounted in the RH side of the instrument panel. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Disposal Air Bag: Service and Repair Air Bag Disposal Deployed Air Bag 1. Dispose of the deployed air bag modules in the same manner as any other part to be scrapped. WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. Undeployed Air Bag, Inoperative WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. 1. Remove the inoperative driver air bag module or passenger air bag module. NOTE: All inoperative air bag modules have been placed on the Mandatory Return List. All discolored or damaged air bag modules should treated the same as any inoperative live air bag being returned. 2. When installing a new driver air bag module, record the necessary information and return the inoperative driver air bag module to Ford Motor Company. NOTE: When installing a new air bag module, a prepaid return postcard is provided with the replacement air bag module. The serial number for the new part and the Vehicle Identification Number (VIN) must be recorded and sent to Ford Motor Company. 3. When installing a new passenger air bag module, record the necessary information and return the inoperative passenger air bag module to Ford Motor Company. Undeployed Air Bag, Scrapped Vehicle Remote Deployment WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Remote deployment is to be performed outdoors with all personnel at least 6.1 meters (20 feet) away to ensure personal safety. Due to the loud report which occurs when the air bag is deployed, hearing protection is required. - Do not place the driver or passenger air bag module with the trim cover or deployment door facing down, as the forces of the deploying air bag can cause it to ricochet and cause personal injury. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Disposal > Page 9289 NOTE: The passenger air bag module is shown. The driver air bag module is similar. 1. Remove the passenger air bag module. 2. Cut the two connector wires on the passenger air bag module, and strip 25 mm (1 in) of insulation from the ends of the wires. 3. Obtain two wires (20 gauge minimum) at least 6.1 meters (20 feet) long and connect one end of each wire to each of the wires on the passenger air bag module. 4. Place the passenger air bag module on a flat surface with the deployment door facing upward in an open outdoor area. 5. Remain at least 6.1 meters (20 feet) away from the passenger air bag module. 6. Deploy the air bag by touching the other ends of the two wires to the terminals of a 12-volt battery. 7. Allow at least ten minutes before approaching the deployed air bag to allow for cooling. 8. Dispose of the deployed air bag module in the same manner as any other part to be scrapped. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Disposal > Page 9290 Air Bag: Service and Repair Removal and Installation Driver's Side WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Air bag modules with discolored or damaged trim covers must be installed new, not repainted. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - To avoid accidental, deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. REMOVAL NOTE: The side air bag sensors are located at or near the base of the B-pillar. - To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the two back cover plugs from the steering wheel. 3. Remove the two driver air bag module retaining bolts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Disposal > Page 9291 4. Remove the driver air bag module. 1 Disconnect the driver air bag module electrical connector. 2 Disconnect the horn switch electrical connector. 3 Remove the driver air bag module. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. - Make sure to tighten the retaining bolts to specification. 2. Prove out the air bag system. Passenger's Side WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and deployment door pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the deployment door face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Disposal > Page 9292 - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Air bag modules with discolored or damaged deployment doors must be installed new, not repainted. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - To avoid accidental, deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. REMOVAL NOTE: The side air bag sensors are located at or near the base of the B-pillar. - To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the instrument panel relay cover. 3. Disconnect the passenger air bag module. 1 Disconnect the electrical connector. 2 Remove the upper retaining bolt. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Disposal > Page 9293 4. Push in the two glove compartment door tabs and position downward. 5. Remove the two lower passenger air bag module retaining bolts. 6. Remove the passenger air bag module. INSTALLATION NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. - Make sure to tighten the retaining bolts to specification. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and Repair > Air Bag Disposal > Page 9294 1. To install, reverse the removal procedure. 2. Prove out the air bag system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications Air Bag Control Module: Specifications Restraint Control Module ..................................................................................................................... ........................................................ 12 Nm (9 Lb-Ft) Grounding Screw (6 mm) ................................. ............................................................................................................................................ 12 Nm (9 Lb-Ft) Crash Sensor Grounding Screw (Weld Nut Repair Screw [8 mm]) ............................................................................................................. 12 Nm (9 Lb-Ft) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 9298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 9299 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Specifications > Page 9300 Air Bag Control Module: Description and Operation The Restraints Control Module (RCM) performs the following functions: - signals the inflators to deploy the air bags in the event of a deployable crash, - monitors the air bag supplemental restraint system (SRS) for faults. - illuminates the air bag indicator if a fault is detected. - flashes the air bag indicator to indicate the Lamp Fault Code (LFC) detected. - communicates through the Data Link Connector (DLC) the current or historical Diagnostic Trouble Codes (DTCs). - signals the Generic Electronic Module (GEM) to activate a chime if the air bag indicator is not available and another SRS fault exists. NOTE: The safing sensor is internal to the RCM and is not serviced separately. The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the RUN position, the RCM will illuminate the air bag indicator located in the instrument cluster. When the ignition is cycled (turned off and then on), the air bag indicator will remain lit for six seconds and then go out. If an SRS fault exists, the air bag indicator will then flash the two-digit LFC. The air bag indicator will flash the LFC five times, then it will remain illuminated for the rest of the key cycle. The RCM will also communicate the current and historical DTCs through the DLC, using the New Generation Star (NGS) Tester. If the air bag indicator does not function, and the system detects a fault condition, the RCM will signal the GEM to activate an audible chime. The chime is a series of five sets of five tone bursts. If the chime is heard, the SRS and the air bag indicator require repair. LFCs are prioritized. If two or more faults occur at the same time, the fault having the highest priority will be displayed first. After that fault has been corrected, the next highest priority fault will be displayed. The RCM includes a backup power supply. This feature provides sufficient backup power to deploy the air bags in the event that the ignition circuit is damaged in a collision before the safing and air bag sensors determine that an air bag deployment is required. The backup power supply will deplete its stored energy approximately one minute after the battery ground cable is disconnected. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Programming A New Restraints Control Module (RCM) Air Bag Control Module: Service and Repair Programming A New Restraints Control Module (RCM) When installing a new Restraints Control Module (RCM) it must be programmed for the applicable vehicle configuration. Program the RCM using the following procedure. 1. Make sure that all of the SRS components are installed in the vehicle and the battery is connected. 2. Insert the FSF card in the NGS. 3. Connect the NGS to the Data Link Connector (DLC). 4. Key to RUN. 5. On the NGS select "Service Bay Functions". 6. Select "RCM-Restraints Control Module". 7. Select: - "Airbag Configuration 14" for vehicle with Passenger Airbag Deactivate Switch. - "Airbag Configuration 15" for vehicle without Passenger Airbag Deactivate Switch. 8. Wait for a process complete confirmation. 9. Key to OFF. 10. Prove out the system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Programming A New Restraints Control Module (RCM) > Page 9303 Air Bag Control Module: Service and Repair Removal And Installation REMOVAL WARNING: To avoid accidental, deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: Repair is made by installing a new part only. If a new part does not correct the condition, in stall the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the lower center instrument panel finish panel. 1 Remove the two push pins. 2 Remove the panel. 3. Disconnect the Restraints Control Module (RCM) electrical connector. 1 Disengage the RCM electrical connector locking clip. 2 Disconnect the RCM electrical connector. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information > Service and Repair > Programming A New Restraints Control Module (RCM) > Page 9304 4. Remove the RCM and bracket assembly. 1 Remove the bracket retaining bolts. 2 Remove the RCM and bracket assembly. INSTALLATION 1. To install, reverse the removal procedure. WARNING: The tightening torque of the restraints control module (RCM) retaining bolts is critical for correct system operation. NOTE: Repair is made by installing a new part only. If a new part does not correct the condition, install the original part and perform the diagnostic procedure again. - Make sure to tighten the retaining bolts to specification. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Description and Operation Air Bag Deactivation Switch: Description and Operation The Passenger Air Bag Deactivation (PAD) switch: - is located on the instrument panel to the right of the climate controls. - contains a Light Emitting Diode (LED) that indicates when the PAD switch is activated (passenger air bag disabled). - allows the passenger air bag deployment circuit to be disabled using the ignition key. - should be used whenever a child safety seat is being used in the front passenger seating position. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information > Description and Operation > Page 9308 Air Bag Deactivation Switch: Service and Repair REMOVAL WARNING: To avoid accidental, deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). NOTE: Repair is made by installing a new part only. If a new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the center instrument panel finish panel. 3. Remove the Passenger Air Bag Deactivation (PAD) switch. 1 Disconnect the electrical connector. 2 Remove the retaining bolts. 3 Remove the PAD switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Repair is made by installing a new part only If a new part does not correct the condition, install the original part and perform the diagnostic procedure again. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 9312 Clockspring Assembly / Spiral Cable: Description and Operation The air bag sliding contact: - is mounted on the steering column, behind the steering wheel. - continuously transfers electrical signals from the driver air bag module to the Restraints Control Module (RCM). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 9313 Clockspring Assembly / Spiral Cable: Service and Repair WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Air bag modules with discolored or damaged trim covers must be installed new, not repainted. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - To avoid accidental, deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. REMOVAL NOTE: The side air bag sensors are located at or near the base of the B-pillar. - To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the driver air bag module. 3. Remove the steering wheel. NOTE: Make sure the wheels are in the straight-ahead position. 4. Apply two strips of masking tape across the air bag sliding contact to prevent accidental rotation. 5. Twist the tilt wheel handle and shank and remove. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 9314 6. Remove the upper instrument panel steering column cover. 7. Remove the junction box fuse/relay panel cover. 8. Remove the lower instrument panel steering column cover. 1 Remove the two retaining bolts and disconnect the parking brake release lever. 2 Remove the two retaining bolts and disconnect the hood release lever. 3 Remove the six retaining bolts. 4 Remove the cover. 9. Remove the lower steering column shroud. 1 Remove the three retaining screws. 2 Remove the shroud. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 9315 10. Remove the ignition switch lock cylinder. 1 Position the lock cylinder to RUN. 2 Using a suitable tool, push upward on the cylinder release tab while pulling the cylinder outward. 11. Remove the upper steering column shroud, 12. Remove the Passive Antitheft System (PATS) transmitter. 1 Remove the retaining screw. 2 Remove the transmitter. 13. Remove the key-in-ignition warning indicator switch. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 9316 14. Disconnect the air bag sliding contact electrical connectors. 1 Separate the electrical connectors from the retaining bracket and disconnect from the harness. 2 Separate the air bag sliding contact wire harness from the clips retaining it to the steering column. 15. Remove the air bag sliding contact. 1 Pry the retaining clips loose. 2 Remove the air bag sliding contact. INSTALLATION 1. To install, reverse the removal procedure. WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 2. Prove out the air bag system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Description and Operation Impact Sensor: Description and Operation WARNING: The Restraints Control Module (RCM) orientation is critical for correct system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) has been involved in a collision in which the center tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, the RCM must be replaced whether or not the air bags have deployed. In addition, make sure the area of the RCM mounting is restored to its original condition. The SRS contains two sensors which are integral to the Restraints Control Module (RCM). The RCM is mounted on the center tunnel under the instrument panel. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side Air Bag Module Side Air Bag: Service and Repair Driver Side Air Bag Module WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Air bag modules with discolored or damaged trim covers must be installed new, not repainted. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - To avoid accidental, deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. REMOVAL NOTE: - The side air bag sensors are located at or near the base of the B-pillar. - To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the two back cover plugs from the steering wheel. 3. Remove the two driver air bag module retaining bolts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side Air Bag Module > Page 9324 4. Remove the driver air bag module. 1 Disconnect the driver air bag module electrical connector. 2 Disconnect the horn switch electrical connector. 3 Remove the driver air bag module. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. - Make sure to tighten the retaining bolts to specification. 2. Prove out the air bag system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side Air Bag Module > Page 9325 Side Air Bag: Service and Repair Passenger Side Air Bag WARNING: - Always wear safety glasses when repairing an air bag supplemental restraint system (SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event of an accidental deployment. - Carry a live air bag module with the air bag and deployment door pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set a live air bag module down with the deployment door face down. This will reduce the risk of injury in the event of an accidental deployment. - After deployment, the air bag surface can contain deposits of sodium hydroxide, a product of the gas generant combustion that is irritating to the skin. Wash your hands with soap and water afterwards. - Never probe the connectors on the air bag module. Doing so can result in air bag deployment, which can result in personal injury. - Air bag modules with discolored or damaged deployment doors must be installed new, not repainted. - Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped with an air bag supplemental restraint system (SRS) is involved in a collision, inspect the sensor mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or any other damaged supplemental restraint system (SRS) components whether or not the air bag is deployed. - To avoid accidental, deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. REMOVAL NOTE: The side air bag sensors are located at or near the base of the B-pillar. - To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). - Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the instrument panel relay cover. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side Air Bag Module > Page 9326 3. Disconnect the passenger air bag module. 1 Disconnect the electrical connector. 2 Remove the upper retaining bolt. 4. Push in the two glove compartment door tabs and position downward. 5. Remove the two lower passenger air bag module retaining bolts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and Repair > Driver Side Air Bag Module > Page 9327 6. Remove the passenger air bag module. INSTALLATION NOTE: Repair is made by installing a new part only. If the new part does not correct the condition, install the original part and perform the diagnostic procedure again. - Make sure to tighten the retaining bolts to specification. 1. To install, reverse the removal procedure. 2. Prove out the air bag system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Standby Power Supply, Air Bag > Component Information > Service Precautions Standby Power Supply: Service Precautions WARNING: - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. - To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Standby Power Supply, Air Bag > Component Information > Service Precautions > Page 9331 Standby Power Supply: Description and Operation The Restraints Control Module (RCM) includes a backup power supply. This feature provides sufficient backup power to deploy the air bags in the event that the ignition circuit is damaged in a collision before the safing and air bag sensors determine that an air bag deployment is required. The backup power supply will deplete its stored energy approximately one minute after the battery ground cable is disconnected. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Description and Operation Malfunction Lamp / Indicator: Description and Operation The air bag indicator will be illuminated when the Restraint Control Module (RCM) sends a ground signal to the instrument cluster. The prove out of the air bag indicator is controlled by the RCM. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications Air Bag Control Module: Specifications Restraint Control Module ..................................................................................................................... ........................................................ 12 Nm (9 Lb-Ft) Grounding Screw (6 mm) ................................. ............................................................................................................................................ 12 Nm (9 Lb-Ft) Crash Sensor Grounding Screw (Weld Nut Repair Screw [8 mm]) ............................................................................................................. 12 Nm (9 Lb-Ft) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 9339 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 9340 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Specifications > Page 9341 Air Bag Control Module: Description and Operation The Restraints Control Module (RCM) performs the following functions: - signals the inflators to deploy the air bags in the event of a deployable crash, - monitors the air bag supplemental restraint system (SRS) for faults. - illuminates the air bag indicator if a fault is detected. - flashes the air bag indicator to indicate the Lamp Fault Code (LFC) detected. - communicates through the Data Link Connector (DLC) the current or historical Diagnostic Trouble Codes (DTCs). - signals the Generic Electronic Module (GEM) to activate a chime if the air bag indicator is not available and another SRS fault exists. NOTE: The safing sensor is internal to the RCM and is not serviced separately. The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in the RUN position, the RCM will illuminate the air bag indicator located in the instrument cluster. When the ignition is cycled (turned off and then on), the air bag indicator will remain lit for six seconds and then go out. If an SRS fault exists, the air bag indicator will then flash the two-digit LFC. The air bag indicator will flash the LFC five times, then it will remain illuminated for the rest of the key cycle. The RCM will also communicate the current and historical DTCs through the DLC, using the New Generation Star (NGS) Tester. If the air bag indicator does not function, and the system detects a fault condition, the RCM will signal the GEM to activate an audible chime. The chime is a series of five sets of five tone bursts. If the chime is heard, the SRS and the air bag indicator require repair. LFCs are prioritized. If two or more faults occur at the same time, the fault having the highest priority will be displayed first. After that fault has been corrected, the next highest priority fault will be displayed. The RCM includes a backup power supply. This feature provides sufficient backup power to deploy the air bags in the event that the ignition circuit is damaged in a collision before the safing and air bag sensors determine that an air bag deployment is required. The backup power supply will deplete its stored energy approximately one minute after the battery ground cable is disconnected. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Programming A New Restraints Control Module (RCM) Air Bag Control Module: Service and Repair Programming A New Restraints Control Module (RCM) When installing a new Restraints Control Module (RCM) it must be programmed for the applicable vehicle configuration. Program the RCM using the following procedure. 1. Make sure that all of the SRS components are installed in the vehicle and the battery is connected. 2. Insert the FSF card in the NGS. 3. Connect the NGS to the Data Link Connector (DLC). 4. Key to RUN. 5. On the NGS select "Service Bay Functions". 6. Select "RCM-Restraints Control Module". 7. Select: - "Airbag Configuration 14" for vehicle with Passenger Airbag Deactivate Switch. - "Airbag Configuration 15" for vehicle without Passenger Airbag Deactivate Switch. 8. Wait for a process complete confirmation. 9. Key to OFF. 10. Prove out the system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Programming A New Restraints Control Module (RCM) > Page 9344 Air Bag Control Module: Service and Repair Removal And Installation REMOVAL WARNING: To avoid accidental, deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage can result. NOTE: Repair is made by installing a new part only. If a new part does not correct the condition, in stall the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the lower center instrument panel finish panel. 1 Remove the two push pins. 2 Remove the panel. 3. Disconnect the Restraints Control Module (RCM) electrical connector. 1 Disengage the RCM electrical connector locking clip. 2 Disconnect the RCM electrical connector. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module > Component Information > Service and Repair > Programming A New Restraints Control Module (RCM) > Page 9345 4. Remove the RCM and bracket assembly. 1 Remove the bracket retaining bolts. 2 Remove the RCM and bracket assembly. INSTALLATION 1. To install, reverse the removal procedure. WARNING: The tightening torque of the restraints control module (RCM) retaining bolts is critical for correct system operation. NOTE: Repair is made by installing a new part only. If a new part does not correct the condition, install the original part and perform the diagnostic procedure again. - Make sure to tighten the retaining bolts to specification. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. - To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming Deactivation Procedure 1. Disconnect the battery ground cable. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the driver air bag module from the vehicle. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set an air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. 4. Connect an air bag simulator to the vehicle harness at the top of the steering column. 5. Disconnect the passenger air bag module electrical connector. 6. Connect an air bag simulator to the vehicle harness. 7. Reconnect the battery ground cable. Reactivation Procedure 1. Disconnect the battery ground cable. WARNING: The air bag simulators must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the air bag simulator from the vehicle harness connector at the top of the steering column. 4. Install the driver air bag module. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. 5. Remove the air bag simulator from the vehicle harness connector at the passenger air bag module. 6. Connect the passenger air bag module electrical connector. 7. Reconnect the battery ground cable. 8. Prove out the system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 9352 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist should be completed following diagnosis or repair of any air bag system concern. 1. Is the connector at the base of the steering column connected? ................................................................................................................................ [ ] 2. Are the air bag modules connected? ............................................................................................... .......................................................................... [ ] 3. Is the Restraints Control Module (RCM) connected? ............................................................................................................................................... [ ] 4. Is the vehicle battery connected? .................................................................................................... .......................................................................... [ ] Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Component Information > Description and Operation Child Restraint: Description and Operation Kit Contents SuperCab Tether Locations Captains Chair Tether Location Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Component Information > Description and Operation > Page 9356 Tether Anchor Locations -- Regular And SuperCab Tether Anchor Locations The (A) SuperCab with captain's chairs has four tether anchor locations. The (B) SuperCab with 60/40 split front bench seats or full front bench seats has five tether anchor locations. The (C) Regular Cab with captain's chairs has one tether anchor location. The (D) Regular Cab with 60/40 split bench seats or full bench seat has two tether anchor locations. For installation procedures and warnings, refer to the installation instructions included with the kit. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Specifications Seat Belt: Specifications Front Seat Safety Belt Anchor Bolts (Regular Cab) .................................................................................................................................. 47 Nm (35 Lb/Ft) Rear Seat Center Occupant Safety Belt Tongue Assembly Bolt ................................................................................................................ 40 Nm (29 Lb/Ft) Safety Belt Guide Bolts ................................................................................................................................... .......................................... 40 Nm (29 Lb/Ft) SuperCab Passenger Front Seat Safety Belt Adjustable D-Ring Bolt ........................................................................................................ 40 Nm (29 Lb/Ft) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection Seat Belt: Service and Repair Cleaning and Inspection 1. Clean the safety belt webbing only with a mild soap solution recommended for cleaning upholstery or carpets. Follow the instructions provided with the soap. WARNING: Do not bleach or re-dye the webbing, as the webbing may weaken. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 9362 Seat Belt: Service and Repair Removal and Installation Rear Seat, Center Passenger Safety Belt Bolt Bit Special Tool(s) REMOVAL 1. Open the 60% and 40% rear seat cushions. 2. Remove the rear seat center occupant safety belt tongue assembly. 1 Use the special tool to remove the bolt. 2 Remove the rear seat center occupant safety belt tongue assembly by pulling the anchor up through the elastic strap on the seat back. INSTALLATION 1. To install, reverse the removal procedure. - Check the restraint system for normal operation. NOTE: Make sure that safety belt webbing is not twisted prior to installation. 60/40 Split and Front Bench Seat, Center Passenger Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 9363 T55 "Torx Plus" Bit Special Tool(s) REMOVAL 1. Remove the front passenger safety belt. 1 Use the special tool to remove the bolt. 2 Feed the belt up through the seat cushion strap and remove the front passenger safety belt tongue assembly. INSTALLATION 1. To install, reverse the removal procedure. - Check the restraint system for normal operation. NOTE: Make sure the tongue webbing is outside the seat side shield, not under the shield. The webbing could be cut if it is routed under the seat side shield. Bucket Seats Safety Belt Bolt Bit Special Tool(s) REMOVAL 1. Remove the floor console. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 9364 2. Remove the passenger seat safety belt buckle. 1 Use the special tool to remove the bolt. 2 Remove the passenger seat safety belt buckle. 3. On manual driver seats, remove the driver seat safety belt buckle. 1 Disconnect the safety belt warning indicator switch electrical connector. 2 Use the special tool to remove the bolt. 3 Remove the driver seat safety belt buckle. 4. On power driver seats, remove the driver side safety belt buckle. 1 Disconnect the safety belt warning indicator switch electrical connector. 2 Remove the driver seat safety belt buckle nut. 3 Remove the driver seat safety belt buckle. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 9365 1. To install, reverse the removal procedure. - Check the restraint system for normal operation. Full Bench Seat T55 "Torx Plus" Bit Special Tool(s) REMOVAL 1. Remove the front center and RH passenger safety belt buckle ends 1 Use the special tool to remove the buckle bolts. 2 Feed the buckle assembly up through the top of the seat cushion and remove the front seat safety belt buckles. 3 Feed the LH driver buckle and center passenger tongue assembly up through the top of the seat cushion and remove the front seat safety belt buckle/tongue assembly. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 9366 1. To install, reverse the removal procedure. - Check the restraint system for normal operation. Rear Seats REMOVAL 1. Remove the 60% or 40% rear seat cushion. 2. Remove the 60% rear seat cushion latch and buckle assembly. 1 Remove the bolts. 2 Remove the 60% rear seat cushion latch and buckle assembly. NOTE: The rear seat safety belt buckles are integral with the rear seat latch assembly. 3. Remove the 40% rear seat cushion latch and buckle assembly. 1 Remove the bolts. 2 Remove the 40% rear seat cushion latch and buckle assembly. NOTE: The rear seat safety belt buckles are integral with the rear seat latch assembly. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 9367 1. To install, reverse the removal procedure. - Check the restraint system for normal operation. 40 Percent Portion of 60/40 Split Bench Safety Belt Bolt Bit Special Tool(s) REMOVAL 1. Remove the driver seat safety belt buckle. 1 Disconnect the safety belt warning indicator switch electrical connector. 2 Use the special tool to remove the bolt. 3 Remove the driver seat safety belt buckle. NOTE: To ease removal, position the 40% seat in its most rearward position and the 60% seat in its most forward position. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 9368 1. To install, reverse the removal procedure. - Check the restraint system for normal operation. 60 Percent Portion of 60/40 Split Bench T55 "Torx Plus" Bit Special Tool(s) REMOVAL 1. Remove the front passenger safety belt. 1 Use the special tool to remove the bolt. 2 Feed the belt through the seat cushion pocket and remove the belt. INSTALLATION 1. To install, reverse the removal procedure. - Check the restraint system for normal operation. Seat Belt Height Adjuster Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 9369 Safety Belt Bolt Bit Special Tool(s) REMOVAL 1. Remove the upper corner trim panel. 2. Remove the height adjuster cover. 3. Remove the shoulder safety belt height adjuster. 1 Use the special tool to remove the two bolts. 2 Remove the shoulder safety belt height adjuster. INSTALLATION 1. To install, reverse the removal procedure. - Check the restraint system for normal operation. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 9370 Seat Belt: Service and Repair Service Procedures Post Collision Inspection 1. Before installing the new safety belt assembly, the safety belt attaching areas must be inspected for damage and distortion. If the attaching points are damaged and distorted, the sheet metal must be reworked back to its original shape and structural integrity. WARNING: All safety belt assemblies including retractors, buckles, front seat belt buckle support assemblies (slide bar), shoulder belt height adjusters, if so equipped, child safety seat tether attachments, and attaching hardware should be inspected after any collision. All belt assemblies should be replaced unless a qualified technician finds the assemblies show no damage and operate properly. Belt assemblies not in use during a collision should also be inspected and replaced if either damage or improper operation is noted. NOTE: Safety belt assemblies should be periodically inspected to make sure they have not become damaged and that they remain in proper operating condition, particularly if they have been subjected to severe stress. 2. Install the new safety belt(s) using the appropriate instructions. Perform the Component Test. Replacement of the Weld Nut and Reinforcement 1. Remove the interior trim panel to expose the suspect anchor point. 2. Determine if the weld nut only or the weld nut and reinforcement and weld nut are missing. If the B- or C- or D-pillar safety belt anchor nuts or reinforcements are stripped or missing, they should be replaced with a new nut or reinforcement. To install a missing weld nut only, proceed to Step 3. 3. Obtain a M12 weld nut and a standard washer. 4. Drill out two 8 mm (5/16 in) diameter holes adjacent to the clearance hole. 5. Obtain a length of copper welding wire and feed through clearance hole in door frame opening until it becomes visible at the access hole. 6. Pull the wire through so that it may be secured to the weld nut and washer. 7. Pull the wire back up to the weld nut clearance hole. 8. Hold the weld nut securely in place. Use the MIG Wire Feed Welder to plug weld the nut in place at the two 8 mm (5/16 in) diameter holes previously drilled. 9. Metal finish as required. 10. Verify the nut is securely in place. Safety Belt Tongue Rotated on Belt 1. Fold the safety belt as indicated. 2. Pull the safety belt tongue over the fold in the safety belt. Regular Cab Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 9371 Safety Belt Bolt Bit Special Tool(s) REMOVAL 1. Remove the upper corner trim panel. 2. Remove the lower corner trim panel. 3. Remove the front safety belt retractor. 1 Use the special tool to remove the bolt. 2 Remove the front safety belt retractor. INSTALLATION 1. To install, reverse the removal procedure. - Check the restraint system for normal operation. NOTE: Make sure that safety belt webbing is not twisted prior to installation. - Make sure that after an Automatic Locking Retraction (ALR) retractor is installed that the retractor is not in the ALR mode of operation when it is installed. Front Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 9372 Safety Belt Bolt Bit Special Tool(s) REMOVAL 1. Disconnect the front seat safety belt adjustable D-ring. 1 Pull back the cover. 2 Use the special tool to remove the bolt. 3 Disconnect the front seat safety belt adjustable D-ring. 2. Remove the scuff plate. 3. Use the special tool to remove the bolt and the front safety belt retractor. 4. Use the special tool to remove the front safety belt anchor bolt. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 9373 1. To install, reverse the removal procedure. - Check the restraint system for normal operation. NOTE: Make sure that safety belt webbing is not twisted prior to installation. - The orientation of the SuperCab LH front retractor anchor is with the vertical leg in the rearward direction. - Make sure that after an Automatic Locking Retraction (ALR) retractor is installed that the retractor is not in the ALR mode of operation when it is installed. Rear Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 9374 Special Tool(s) REMOVAL 1. Remove the upper rear corner trim panel. 2. Remove the lower corner trim panel. 3. Remove the rear safety belt retractor. 1 Use the special tool to remove the bolt. 2 Remove the rear safety belt retractor. INSTALLATION 1. To install, reverse the removal procedure. - Check the restraint system for normal operation. NOTE: Make sure that safety belt webbing is not twisted prior to installation. The SuperCab rear retractor anchor should be positioned with the vertical leg facing outboard. Shoulder Safety Belt Height Adjuster With Stripped Weld Nuts Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 9375 D-Ring Installation Kit Special Tool(s) 1. Remove the upper corner trim panels. 2. Use the half-inch drill provided in D-Ring Installation Kit 100-F012 or equivalent to drill out the damaged threads in the upper B-pillar structure. 3. Apply a suitable lubricant to the M14 x 1.5 tap provided in D-Ring Installation Kit 100-F012 and tap new threads. NOTE: After each rotation, back tap off slightly to remove new cuttings and be sure to clean out any chips before proceeding. 4. Use a threaded insert provided in D-Ring Installation Kit 100-F012 or equivalent and screw it into the retapped hole until it is slightly below the surface of the hole. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Cleaning and Inspection > Page 9376 5. Use a hammer to lightly tap the installation tool provided in D-Ring Installation Kit 100-F012 several times to drive down the insert keys. NOTE: If the two hex-head bolts on the front seat shoulder strap adjuster are not stripped, install the height adjuster to the body using proper service procedures. If the front seat shoulder strap adjuster bolts are stripped, replace the adjuster. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Specifications Seat Belt Buckle: Specifications Driver Seat Safety Belt Buckle Nut (Power) ............................................................................................................................................. 35 Nm (26 Lb/Ft) Front Seat Safety Belt Buckle Bolts (Floor Mounted) ............................................................................................................................... 47 Nm (35 Lb/Ft) Rear Seat Safety Belt Buckle Bolts ................................................................................................................................................. 21-29 Nm (16-21 Lb/Ft) Safety Belt Buckle Bolts (Front Bucket, 40 Percent Bench) ..................................................................................................................... 35 Nm (26 Lb/Ft) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Bucket Seats Seat Belt Buckle: Service and Repair Bucket Seats Safety Belt Bolt Bit Special Tool(s) REMOVAL 1. Remove the floor console. 2. Remove the passenger seat safety belt buckle. 1 Use the special tool to remove the bolt. 2 Remove the passenger seat safety belt buckle. 3. On manual driver seats, remove the driver seat safety belt buckle. 1 Disconnect the safety belt warning indicator switch electrical connector. 2 Use the special tool to remove the bolt. 3 Remove the driver seat safety belt buckle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Bucket Seats > Page 9382 4. On power driver seats, remove the driver side safety belt buckle. 1 Disconnect the safety belt warning indicator switch electrical connector. 2 Remove the driver seat safety belt buckle nut. 3 Remove the driver seat safety belt buckle. INSTALLATION 1. To install, reverse the removal procedure. - Check the restraint system for normal operation. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Bucket Seats > Page 9383 Seat Belt Buckle: Service and Repair Full Bench Seat T55 "Torx Plus" Bit Special Tool(s) REMOVAL 1. Remove the front center and RH passenger safety belt buckle ends 1 Use the special tool to remove the buckle bolts. 2 Feed the buckle assembly up through the top of the seat cushion and remove the front seat safety belt buckles. 3 Feed the LH driver buckle and center passenger tongue assembly up through the top of the seat cushion and remove the front seat safety belt buckle/tongue assembly. INSTALLATION 1. To install, reverse the removal procedure. - Check the restraint system for normal operation. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Bucket Seats > Page 9384 Seat Belt Buckle: Service and Repair Rear Seats REMOVAL 1. Remove the 60% or 40% rear seat cushion. 2. Remove the 60% rear seat cushion latch and buckle assembly. 1 Remove the bolts. 2 Remove the 60% rear seat cushion latch and buckle assembly. NOTE: The rear seat safety belt buckles are integral with the rear seat latch assembly. 3. Remove the 40% rear seat cushion latch and buckle assembly. 1 Remove the bolts. 2 Remove the 40% rear seat cushion latch and buckle assembly. NOTE: The rear seat safety belt buckles are integral with the rear seat latch assembly. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Bucket Seats > Page 9385 1. To install, reverse the removal procedure. - Check the restraint system for normal operation. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Bucket Seats > Page 9386 Seat Belt Buckle: Service and Repair 40 Percent Portion of 60/40 Split Bench Safety Belt Bolt Bit Special Tool(s) REMOVAL 1. Remove the driver seat safety belt buckle. 1 Disconnect the safety belt warning indicator switch electrical connector. 2 Use the special tool to remove the bolt. 3 Remove the driver seat safety belt buckle. NOTE: To ease removal, position the 40% seat in its most rearward position and the 60% seat in its most forward position. INSTALLATION 1. To install, reverse the removal procedure. - Check the restraint system for normal operation. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Bucket Seats > Page 9387 Seat Belt Buckle: Service and Repair 60 Percent Portion of 60/40 Split Bench T55 "Torx Plus" Bit Special Tool(s) REMOVAL 1. Remove the front passenger safety belt. 1 Use the special tool to remove the bolt. 2 Feed the belt through the seat cushion pocket and remove the belt. INSTALLATION 1. To install, reverse the removal procedure. - Check the restraint system for normal operation. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Extension > Component Information > Description and Operation Seat Belt Extension: Description and Operation In certain cases, the safety belt may be too short even when it is fully extended. About 20 cm (8 inches) can be added to the belt length by using a safety belt extension. Safety belt extensions are available through the dealership parts department at no cost. Safety belt extensions are only available with black webbing. There are two extension assemblies available, one for the front seating position and one for the rear seating position and they are not interchangeable. Use only extensions manufactured by the same supplier as the safety belt. Manufacturer identification is located at the end of the webbing on the label. Also, use the safety belt extension only if the safety belt is too short for you when fully extended. Do not use the extension to change the fit of the shoulder belt across the torso. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Specifications Seat Belt Height Adjuster: Specifications Shoulder Safety Belt Height Adjuster Bolts .............................................................................................................................................. 40 Nm (29 Lb/Ft) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Removal and Installation Seat Belt Height Adjuster: Service and Repair Removal and Installation Safety Belt Bolt Bit Special Tool(s) REMOVAL 1. Remove the upper corner trim panel. 2. Remove the height adjuster cover. 3. Remove the shoulder safety belt height adjuster. 1 Use the special tool to remove the two bolts. 2 Remove the shoulder safety belt height adjuster. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Removal and Installation > Page 9396 1. To install, reverse the removal procedure. - Check the restraint system for normal operation. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Removal and Installation > Page 9397 Seat Belt Height Adjuster: Service and Repair Shoulder Safety Belt Height Adjuster With Stripped Weld Nuts D-Ring Installation Kit Special Tool(s) 1. Remove the upper corner trim panels. 2. Use the half-inch drill provided in D-Ring Installation Kit 100-F012 or equivalent to drill out the damaged threads in the upper B-pillar structure. 3. Apply a suitable lubricant to the M14 x 1.5 tap provided in D-Ring Installation Kit 100-F012 and tap new threads. NOTE: After each rotation, back tap off slightly to remove new cuttings and be sure to clean out any chips before proceeding. 4. Use a threaded insert provided in D-Ring Installation Kit 100-F012 or equivalent and screw it into the retapped hole until it is slightly below the surface of the hole. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information > Service and Repair > Removal and Installation > Page 9398 5. Use a hammer to lightly tap the installation tool provided in D-Ring Installation Kit 100-F012 several times to drive down the insert keys. NOTE: If the two hex-head bolts on the front seat shoulder strap adjuster are not stripped, install the height adjuster to the body using proper service procedures. If the front seat shoulder strap adjuster bolts are stripped, replace the adjuster. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Description and Operation Seat Belt Reminder Lamp: Description and Operation The seat belt switch is hardwired to the Generic Electronic Module (GEM) or Central Timer Module (CTM). The safety belt warning indicator will be illuminated when the GEM/CTM sends a ground signal to the instrument cluster. The safety belt indicator will prove out when the ignition switch is placed in the START position and then in the RUN position. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Description and Operation > Page 9402 Seat Belt Reminder Lamp: Testing and Inspection Refer to Instrument Panel/Testing and Inspection/Procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Specifications Seat Belt Retractor: Specifications Safety Belt Retractor Bolts .................................................................................................................. ...................................................... 40 Nm (29 Lb/Ft) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Specifications > Page 9406 Seat Belt Retractor: Description and Operation Dual Locking Mode Retractors NOTE: When replacing a dual locking mode retractor, the retractor should be checked to make sure it is not in the Automatic Locking Retractor (ALR) mode after installation in the stowed position. All outboard continuous-loop, three-point retractor systems, except the driver position, are equipped with the dual locking mode system. The Emergency Locking Retractor (ELR) mode will allow the occupant freedom of movement, locking tight only on hard braking, hard cornering, or an impact of approximately 8 km/h (5 mph). The ELR mode helps to reduce the forward movement of the driver and passengers. The ELR mode is continuously in operation at all seating positions. The ALR portion of this system does not allow the occupant freedom of movement. The ALR mode is used when locking a child seat in an outboard seating position or when a tight belt fit is desired. The ALR mode is disengaged when the webbing is free to move in or out of the retractor. The ALR mode is automatically engaged when the webbing is fully extracted from the retractor and then allowed to retract. As the webbing is retracted back onto the spool, an audible clicking sound is made indicating the retractor is in ALR mode. The ALR mode is automatically disengaged when most of the webbing is retracted back onto the spool. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Regular Cab Seat Belt Retractor: Service and Repair Regular Cab Safety Belt Bolt Bit Special Tool(s) REMOVAL 1. Remove the upper corner trim panel. 2. Remove the lower corner trim panel. 3. Remove the front safety belt retractor. 1 Use the special tool to remove the bolt. 2 Remove the front safety belt retractor. INSTALLATION 1. To install, reverse the removal procedure. - Check the restraint system for normal operation. NOTE: Make sure that safety belt webbing is not twisted prior to installation. - Make sure that after an Automatic Locking Retraction (ALR) retractor is installed that the retractor is not in the ALR mode of operation when it is installed. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Regular Cab > Page 9409 Seat Belt Retractor: Service and Repair Supercab Front Safety Belt Bolt Bit Special Tool(s) REMOVAL 1. Disconnect the front seat safety belt adjustable D-ring. 1 Pull back the cover. 2 Use the special tool to remove the bolt. 3 Disconnect the front seat safety belt adjustable D-ring. 2. Remove the scuff plate. 3. Use the special tool to remove the bolt and the front safety belt retractor. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Regular Cab > Page 9410 4. Use the special tool to remove the front safety belt anchor bolt. INSTALLATION 1. To install, reverse the removal procedure. - Check the restraint system for normal operation. NOTE: Make sure that safety belt webbing is not twisted prior to installation. - The orientation of the SuperCab LH front retractor anchor is with the vertical leg in the rearward direction. - Make sure that after an Automatic Locking Retraction (ALR) retractor is installed that the retractor is not in the ALR mode of operation when it is installed. Rear Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Regular Cab > Page 9411 Special Tool(s) REMOVAL 1. Remove the upper rear corner trim panel. 2. Remove the lower corner trim panel. 3. Remove the rear safety belt retractor. 1 Use the special tool to remove the bolt. 2 Remove the rear safety belt retractor. INSTALLATION 1. To install, reverse the removal procedure. - Check the restraint system for normal operation. NOTE: Make sure that safety belt webbing is not twisted prior to installation. The SuperCab rear retractor anchor should be positioned with the vertical leg facing outboard. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Warning Timer > Component Information > Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Description and Operation Air Bag Deactivation Switch: Description and Operation The Passenger Air Bag Deactivation (PAD) switch: - is located on the instrument panel to the right of the climate controls. - contains a Light Emitting Diode (LED) that indicates when the PAD switch is activated (passenger air bag disabled). - allows the passenger air bag deployment circuit to be disabled using the ignition key. - should be used whenever a child safety seat is being used in the front passenger seating position. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch > Component Information > Description and Operation > Page 9419 Air Bag Deactivation Switch: Service and Repair REMOVAL WARNING: To avoid accidental, deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). NOTE: Repair is made by installing a new part only. If a new part does not correct the condition, install the original part and perform the diagnostic procedure again. 1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the center instrument panel finish panel. 3. Remove the Passenger Air Bag Deactivation (PAD) switch. 1 Disconnect the electrical connector. 2 Remove the retaining bolts. 3 Remove the PAD switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Repair is made by installing a new part only If a new part does not correct the condition, install the original part and perform the diagnostic procedure again. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Description and Operation Impact Sensor: Description and Operation WARNING: The Restraints Control Module (RCM) orientation is critical for correct system operation. If a vehicle equipped with an air bag Supplemental Restraint System (SRS) has been involved in a collision in which the center tunnel area has been damaged, inspect the mounting and bracket for deformation. If damaged, the RCM must be replaced whether or not the air bags have deployed. In addition, make sure the area of the RCM mounting is restored to its original condition. The SRS contains two sensors which are integral to the Restraints Control Module (RCM). The RCM is mounted on the center tunnel under the instrument panel. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Accessory Delay Relay: Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 9428 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 9429 Accessory Delay Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 9430 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Specifications Antenna: Specifications Antenna mast 4 Nm Inner fender splash shield screws 10-14 Nm Radio antenna base screws 2 Nm Wheelhouse moulding screws 1.6-2.0 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Specifications > Page 9434 Antenna: Description and Operation The antenna and related components consist of the: - radio antenna lead-in cable. - antenna mast. - radio antenna base cap. - radio antenna base and gasket assembly. The antenna receives AM and FM waves. The radio waves are sent to the audio unit through the radio antenna lead-in cable. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Specifications > Page 9435 Antenna: Service and Repair Cable - Lead In REMOVAL 1. On 4x4 vehicles, remove the front wheel opening moulding. 1 Remove the pin-type retainer. 2 Remove the screws. 3 Carefully pull the wheel opening moulding to release the nine clips and remove the front wheel opening moulding. 2. Remove the inner fender splash shield. 1 Remove the screws. 2 Pull the inner fender splash shield to release the clips. 3. Disconnect the radio antenna lead-in cable from the antenna base. 4. Remove the audio unit. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Specifications > Page 9436 5. Push the radio antenna lead-in cable into the passenger compartment. 1 Disconnect the antenna clip from the sheet metal. 2 Push the grommet into the passenger compartment. 3 Push the radio antenna lead-in cable into the passenger compartment. 6. Remove the radio antenna lead-in cable. 1 Disconnect the three cable locators from the lower metal Instrument Panel (I/P) channel. 2 Remove the radio antenna lead-in cable from under the instrument panel. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Specifications > Page 9437 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module > Page 9443 Alarm Module: Diagrams Remote Anti-Theft Personality Module Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module > Page 9444 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Module Replacement Alarm Module: Service and Repair Module Replacement REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2 Insert a punch in the access hole of the steering column and press the release tab while pushing out the ignition switch lock cylinder. 3. Unscrew and remove the tilt wheel handle and shank. 4. Remove the instrument panel steering column cover. 5. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the lower steering column shroud. 3 Remove the upper steering column shroud. NOTE: The steering wheel has been removed for clarity. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Module Replacement > Page 9447 6. Remove the anti-theft transceiver module. 1 Remove the screw from the bottom of the transceiver module. 2 Disconnect the electrical connector and remove the module. NOTE: Only apply pressure or leverage below the key cylinder lower rib. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Module Replacement > Page 9448 Alarm Module: Service and Repair Remote Anti-Theft Personality Module REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the LH front door scuff plate. 3. Remove the LH cowl side trim panel. 4. Disconnect the two Remote Anti-Theft Personality (RAP) module electrical connectors. 1 Disconnect C257. 2 Disconnect C256. NOTE: If C256 is disconnected first, an inadvertent IGNTAM alarm event (AL__EVT) will be stored and the alarm will sound. The alarm must be disarmed by the remote unlock button or a key in the door lock cylinder to UNLOCK. To avoid this condition, disconnect (1) C257 before (2) C256 and reconnect (2) C256 before (1) C257. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Module Replacement > Page 9449 5. Remove the RAP module nuts and the RAP module. INSTALLATION 1. To install, reverse the removal procedure. NOTE When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. - To avoid inadvertent alarm activation, reconnect C256 first. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics Keyless Entry Key-Pad: Technical Service Bulletins Keyless Entry - Keypad Diagnostics TSB 06-15-8 08/07/06 KEYPAD DIAGNOSTICS - DEALER INSTALLED ACCESSORY FORD: 1998-2006 Taurus 1999-2003 Escort 1999-2006 Mustang 2000-2006 Focus 2002-2005 Thunderbird 2005-2006 Five Hundred, Freestyle 2006 Crown Victoria, Fusion 1998-2006 Expedition, Explorer, F-150, Ranger 1999 F-250 Light Duty 1999-2003 Windstar 1999-2006 F-Super Duty 2000-2005 Excursion 2000-2006 E-Series 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004 F-150 Heritage 2004-2006 Freestar LINCOLN: 1998-2006 Town Car 2000-2006 Lincoln LS 2006 Zephyr 1998-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006 Mark LT MERCURY: 1998-2005 Sable 1999-2002 Cougar 2005-2006 Montego 2006 Grand Marquis, Milan 1998-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner ISSUE Some vehicles may experience a concern with the keyless entry keypad. In order to properly diagnose the concern with the keyless entry keypad, it is important to identify whether the keypad is a factory installed style (wired) or a Genuine Ford Accessory (GFA) radio frequency (RF) style keypad. ACTION Use the following Service Procedure to identify GFA RF keypads and provide diagnostic service tips. SERVICE PROCEDURE IDENTIFICATION: 1. Production installed keyless entry keypads are mounted flush with the surface of the vehicle and are wired directly to the module controlling the vehicle's keyless entry system. This style keypad can be diagnosed using the appropriate Workshop Manual (WSM), Section 501-14. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 9455 2. Dealer installed GFA RF keypads are adhesive backed and protrude approximately 1/2" (13 mm) from the surface of the vehicle and there are no specific diagnostics available in the WSM (Figure 1). NOTE THIS RF KEYPAD WAS ALSO US[D IN PRODUCTION ON 2004 F-SUPER DUTY VEHICLES BUILT PRIOR TO 12/3/2003. REFER TO WSM, SECTION 501-14 FOR RF KEYPAD DIAGNOSTICS FOR THESE VEHICLES. GENUINE FORD ACCESSORY KEYPAD DIAGNOSTIC TIPS 1. The keypad operates similarly to a remote keyless entry (RKE) transmitter and is programmed using a similar procedure. Although the RF keypad is not specifically addressed in the WSM, the RKE transmitter programming portion of the WSM, Section 501-14 can be used as a guide NOTE THE 7-8 AND 9-0 BUTTONS ON THE KEYPAD MUST BE PRESSED SIMULTANEOUSLY DURING THE PROCEDURE IN ORDER FOR THE KEYPAD TO BE RECOGNIZED AS AN ADDITIONAL REMOTE TRANSMITTER. Since the GFA RF keypad is essentially another RKE transmitter, the transmitter diagnostic pinpoint tests in the vehicle's WSM can also be referenced even though the buttons serving the lock / unlock functions will differ 2. The GFA RF keypad is serviced as an assembly. The internal battery cannot be replaced separately. 3. If the master code or owner selectable code is lost or forgotten, the GFA RF keypad must be replaced. These codes are not stored in any vehicle module (with the exception of 2004 F-Super Duty vehicles produced prior to 12/3/2003). 4. The GFA RF keypad and all RKE transmitters (the number of transmitters allowable will vary by vehicle) must be reprogrammed together anytime the keypad is replaced, an RKE transmitter is replaced, or the module controlling the keyless entry system on the vehicle (GEM/SJB/VSM/DDM etc.) is replaced. NOTE THERE IS AN EXCEPTION TO TIP 4 FOR VEHICLES EQUIPPED WITH INTEGRATED KEYHEAD TRANSMITTERS (IKTs) (FUSION/MILAN/ZEPHYR). THE GFA RF KEYPADS FOR VEHICLES WITH IKTs MUST BE PROGRAMMED INDEPENDENTLY FROM THE IKTs. TURN THE IGNITION FROM "OFF" TO "RUN" 8 TIMES WITHIN 10 SECONDS, WITH THE 8TH TIME ENDING IN "RUN". THE DOOR LOCKS WILL CYCLE TO CONFIRM ENTERING PROGRAMMING MODE. PRESS THE 7-8 AND 9-0 BUTTON ON THE KEYPAD SIMULTANEOUSLY TO SEND A LOCK SIGNAL. TURN IGNITION TO OFF. THE LOCKS WILL CYCLE AGAIN TO INDICATE THE END OF THE PROGRAMMING MODE. 5. The keypad will normally illuminate for 5 seconds after one or more buttons are pressed, and the illumination will immediately turn off if the 7-8 and 9-0 buttons are pressed simultaneously (lock all doors). The keypad contains an optical sensor and will not illuminate under bright lighting conditions. The keypad may only illuminate briefly in colder temperatures in order to maximize the battery power available to transmit a lock/unlock signal. The temperature at which this occurs will vary depending upon the keypad battery age and condition. Both of these conditions are a normal function of the Power Save Mode and do not indicate a need to replace the keypad. 6. After entering the keypad code, the system may unlock the driver's door, lock it, then unlock it again, and the keypad will not even briefly illuminate. This is the Alert Mode and is an indication that battery power is very low and the keypad must be replaced. 7. The keypad also contains an Anti-scan feature. If the wrong code has been entered 7 times (35 consecutive button presses) the keypad is disabled for one minute and the keypad lamp will flash during this time. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 9456 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 14A626 42 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams Keyless Entry Module: Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Page 9460 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair Keyless Entry Transmitter: Service and Repair Programming NOTE: ^ All keyless entry remote transmitters must be programmed at the same time. ^ To program (or reprogram) the keyless entry remote transmitter into the RAP module, perform the following steps: 1. Turn the ignition switch from OFF to RUN 8 times within 10 seconds, ending in RUN. If the RAP module has successfully entered program mode, it will lock and then unlock all doors. 2. Within 20 seconds, press any button on a keyless entry remote transmitter, and the doors will lock and then unlock to confirm that each keyless entry remote transmitter has been programmed. Repeat this step for each transmitter. 3. If the door locks do not respond for any keyless entry remote transmitter, wait several seconds and press the button again. If the door locks still fail to respond, refer to Inspection and Verification. See: Testing and Inspection/Initial Inspection and Diagnostic Overview 4. Turn the ignition switch to the OFF position, or wait up 20 seconds after step 2, to exit program mode. If a keyless entry remote transmitter has been programmed (or reprogrammed), the RAP module will lock and unlock all doors one last time to confirm. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator > Component Information > Description and Operation Security Lamp/Indicator: Description and Operation The THEFT indicator provides Passive Anti-Theft System (PATS) prove out. The THEFT indicator will prove out for three seconds following the ignition switch cycle and will flash following the ignition OFF to indicate that PATS is active. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems > System Information > System Diagnosis Collision Avoidance and Parking Assist Systems: Testing and Inspection Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Technical Service Bulletins > Customer Interest for General Module: > 99-21-3 > Oct > 99 > Autolock System - Functions Not Operating Properly General Module: Customer Interest Autolock System - Functions Not Operating Properly Article No 99-21-3 10/18/99 AUTO-LOCK - AUTO-LOCK FUNCTIONS NOT OPERATING PROPERLY - VEHICLES BUILT FROM 6/3/1999 THROUGH 6/8/1999 FORD: 1999 F-150, F-250 LD ISSUE The Auto-Lock Functions may not be operating properly. This may consist of the relock function inoperative after initial lock or door locks engaging with door open/ajar. Additionally, the double chirp horn alert which indicates door ajar does not operate when the key fob lock button is actuated. These may be due to the door ajar circuit missing from the Generic Electronic Module (GEM) to the Remote Anti-theft Personality (RAP) Module. ACTION Install missing Circuit 999. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the instrument panel fuse junction panel. Refer to the 1999 F-150/250 Workshop Manual, Page 419-10-3, Removal and Installation - Module GEM/CTM. 2. Disengage pin locking bar on C240 connector (GEM 16-way connector) and insert Circuit 999 (LB/W, jumper XL3Z-14A411-BA) into connector location Pin # 3 (Figure 1). Reinsert locking bar. 3. Remove left scuff plate and kick panel to access the C247F connector. 4. Route jumper wire along the -14401- harness to C247F connector at the -14A005- harness in left kick panel area. 5. Remove C247F connector (gray 16-way connector) from finger bracket and disconnect from mating connector. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Technical Service Bulletins > Customer Interest for General Module: > 99-21-3 > Oct > 99 > Autolock System - Functions Not Operating Properly > Page 9478 6. Disengage and remove red locking spacer from C247F connector and insert Circuit 999 (LB/W, jumper XL3Z-14A411-BA) into connector location Pin # 3 (Figure 2). Reinsert red locking spacer. Spot tape jumper circuit along -14401-harness to the -14A005- harness. 7. Reconnect -14401- connector to -14A005- 16-way connector and reattach to finger bracket. 8. Reinstall left kick panel and scuff plate. 9. Reassemble instrument panel fuse junction panel and GEM per Workshop Manual, Page 419-10-3. 10. To functionally test repair, ensure either the driver/passenger door is open, press lock button on key fob twice, and listen for two horn chirps. 11. Connect New Generation Star (NGS) Tester to the vehicle and clear all codes. Then test RAP and GEM modules for any system failure induced during the repair procedure. PART NUMBER PART NAME XL3Z-14A411-BA Jumper Harness OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 992103A Repair Door Ajar Circuit 0.9 Hrs. DEALER CODING CONDITION BASIC PART NO. CODE 14A411 39 OASIS CODES: 112000, 203000, 203200, 205000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for General Module: > 99-21-3 > Oct > 99 > Autolock System - Functions Not Operating Properly General Module: All Technical Service Bulletins Autolock System - Functions Not Operating Properly Article No 99-21-3 10/18/99 AUTO-LOCK - AUTO-LOCK FUNCTIONS NOT OPERATING PROPERLY - VEHICLES BUILT FROM 6/3/1999 THROUGH 6/8/1999 FORD: 1999 F-150, F-250 LD ISSUE The Auto-Lock Functions may not be operating properly. This may consist of the relock function inoperative after initial lock or door locks engaging with door open/ajar. Additionally, the double chirp horn alert which indicates door ajar does not operate when the key fob lock button is actuated. These may be due to the door ajar circuit missing from the Generic Electronic Module (GEM) to the Remote Anti-theft Personality (RAP) Module. ACTION Install missing Circuit 999. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the instrument panel fuse junction panel. Refer to the 1999 F-150/250 Workshop Manual, Page 419-10-3, Removal and Installation - Module GEM/CTM. 2. Disengage pin locking bar on C240 connector (GEM 16-way connector) and insert Circuit 999 (LB/W, jumper XL3Z-14A411-BA) into connector location Pin # 3 (Figure 1). Reinsert locking bar. 3. Remove left scuff plate and kick panel to access the C247F connector. 4. Route jumper wire along the -14401- harness to C247F connector at the -14A005- harness in left kick panel area. 5. Remove C247F connector (gray 16-way connector) from finger bracket and disconnect from mating connector. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for General Module: > 99-21-3 > Oct > 99 > Autolock System - Functions Not Operating Properly > Page 9484 6. Disengage and remove red locking spacer from C247F connector and insert Circuit 999 (LB/W, jumper XL3Z-14A411-BA) into connector location Pin # 3 (Figure 2). Reinsert red locking spacer. Spot tape jumper circuit along -14401-harness to the -14A005- harness. 7. Reconnect -14401- connector to -14A005- 16-way connector and reattach to finger bracket. 8. Reinstall left kick panel and scuff plate. 9. Reassemble instrument panel fuse junction panel and GEM per Workshop Manual, Page 419-10-3. 10. To functionally test repair, ensure either the driver/passenger door is open, press lock button on key fob twice, and listen for two horn chirps. 11. Connect New Generation Star (NGS) Tester to the vehicle and clear all codes. Then test RAP and GEM modules for any system failure induced during the repair procedure. PART NUMBER PART NAME XL3Z-14A411-BA Jumper Harness OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 992103A Repair Door Ajar Circuit 0.9 Hrs. DEALER CODING CONDITION BASIC PART NO. CODE 14A411 39 OASIS CODES: 112000, 203000, 203200, 205000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions General Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9487 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9488 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9489 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9490 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9491 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9492 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9493 General Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9494 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9495 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9496 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9497 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9498 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9499 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9500 General Module: Connector Views Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9501 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9502 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9503 General Module: Electrical Diagrams Diagram 59-1 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9504 Diagram 59-2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9505 Diagram 59-3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9506 Diagram 59-4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Diagrams > Page 9507 General Module: Description and Operation NOTE - Each vehicle has either a Generic Electronic Module (GEM) or Central Timer Module (CTM). The difference in functionality is defined in the GEM/CTM Feature Matrix. - The GEM/CTM inputs and outputs are designed to withstand continuous exposure to a short circuit to ground or battery voltage without being damaged. The multifunction modules consist of the following: - Remote Anti-Theft Personality (RAP) module - Central Timer Module (CTM) with diagnostic connector - Generic Electronic Module (GEM) GEM/CTM Feature Matrix Ignition Switch Positions The position of the ignition switch is very important to proper GEM/CTM operation. Often times, erratic or unexpected operation can be traced to problems on these GEM/CTM inputs. The following is a brief description of five ignition switch positions. When the ignition switch is in the RUN position, battery voltage should be present at the GEM/CTM RUN and RUN/ACC input terminals. When the ignition switch is in the ACC position, battery voltage should be present at the GEM/CTM RUN/ACC input terminal only. When the ignition switch is in the START position, battery voltage should be present at the GEM/CTM start/clutch depressed input. The GEM module does not have an OFF or LOCK switch state input. The GEM will assume the OFF or LOCK position when there are no RUN, ACC, or START signals present. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Diagrams > Page 9508 General Module: Service and Repair Generic Electronic (GEM)/Central Timer (CTM) Module REMOVAL 1. Disconnect the battery ground cable. CAUTION Prior to removal of the module, it is necessary to upload module configuration information to New Generation STAR (NGS) Tester. This information needs to be downloaded into the new module once installed. - Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the steering column cover. 3. Remove the (A) bulkhead electrical connectors from the (B) instrument panel fuse junction panel. 4. Remove the (A) instrument panel fuse junction panel bolts and remove the (B) interior fuse junction panel nuts. 5. Disconnect the (A) Generic Electronic Module (GEM)/Central Timer Module (CTM) electrical connectors from the (B) GEM/CTM. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > General Module > Component Information > Diagrams > Page 9509 6. Remove the screws and the GEM/CTM. INSTALLATION 1. To install, reverse the removal procedure. - Check for proper operation. CAUTION: Once the new module is installed, it is necessary to download the module configuration information from the New Generation STAR (NGS) Tester into the new module. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Specifications CD Changer: Specifications CD Changer Nuts ................................................................................................................................ ......................................................... 9 N.m (80 Lb-In) CD Changer Screws ....................................... .............................................................................................................................................. 3 N.m (27 Lb-In) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Service and Repair > Regular Cab CD Changer: Service and Repair Regular Cab REMOVAL 1. Disconnect the battery ground cable. 2. Remove the CD changer cover and electrical connector cover. 3. If equipped, remove the rear storage compartment. 1 Remove the nuts. 2 Remove the rear storage compartment. 4. Remove the CD changer. 1 Remove the nuts. 2 Disconnect the electrical connector. 3 Remove the CD changer. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Service and Repair > Regular Cab > Page 9517 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Service and Repair > Regular Cab > Page 9518 CD Changer: Service and Repair Supercab REMOVAL 1. Disconnect the battery ground cable. 2. Remove the mat at bottom the of the console bin and remove the screws. - To ease removal of the trim panel, pull the front edge back and lift out. 3. Remove the screws and pull out the CD changer and bracket. 4. Disconnect the electrical connectors. 5. Remove the screws. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > CD Changer > Component Information > Service and Repair > Regular Cab > Page 9519 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers Radio/Stereo Noise Filter: Customer Interest Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9529 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9530 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9531 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9532 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9533 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9534 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9535 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers Radio/Stereo Noise Filter: All Technical Service Bulletins Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9541 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9542 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9543 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9544 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9545 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9546 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9547 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers Speaker: Customer Interest Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 9556 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 9557 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 9558 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 9559 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 9560 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 9561 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 9562 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers Speaker: All Technical Service Bulletins Fuel Pump - Whine Heard Through Radio Speakers Article No. 01-7-3 04/16/01 ^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH ENTERTAINMENT OR TWO - WAY RADIO SPEAKER ^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING" NOISE IN SPEAKERS CAUSED BY FUEL PUMP ^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR TWO-WAY RADIO FORD: 1990-1994 TEMPO 1990-1997 PROBE, THUNDERBIRD 1990-1999 ESCORT, MUSTANG, TAURUS 1990-2001 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990 BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1990-1999 F-250 LD 1990-2001 ECONOLINE, F-150, RANGER 1991-2001 EXPLORER 1995-2001 WINDSTAR 1997-2001 EXPEDITION 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE LINCOLN: 1990-1992 MARK VII 1990-1999 CONTINENTAL 1990-2001 TOWN CAR 1997-1998 MARK VIII 1998-2001 NAVIGATOR MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2001 GRAND MARQUIS 1991-1999 TRACER 1997-1999 MYSTIQUE 1999 COUGAR 2001 SABLE 1993-2001 VILLAGER 1997-2001 MOUNTAINEER This TSB article is being republished in its entirety to update the model year vehicles. ISSUE A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump. ACTION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9568 Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists, then refer to the Service Procedure for repair details. NOTE SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL PUMP ON MULTI-TANK VEHICLES. NOTE THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999 RANGER 3.0L FFVS. TEST PROCEDURE Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the fuel pump and this fix will not be effective. The following procedure will help determine if the fuel pump is the cause of the radio noise: 1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition key - you may need to put the ignition key in the Accessory position). 2. Turn the ignition key to the Run position (do not start the engine). 3. The fuel pump should run for about 1 second with the key in the Run position with the engine not running. Listen for noise in the radio. If noise is present while the pump is running and stops when the pump stops, then the noise is being generated by the pump and this procedure should help. SERVICE PROCEDURE 1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year Workshop Manual for removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9569 2. On vehicles without a fuel delivery module, remove the negative and positive connectors from the fuel pump, Figure 1. a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the wires. b. Connect the RFI filter connectors to the spade terminal on the fuel pump. c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections. NOTE HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9570 TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9571 3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2. a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and black to black). Use heat shrink tubing over soldering connections. b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat shrink tubing over soldered connections. NOTE: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9572 HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF THE CONNECTIONS. NOTE: FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION. SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS. WARNING ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR APPLYING SHRINK TUBING. 4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101) to prevent rattling in the tank, Figures 1 and 2. 5. Reinstall the fuel pump sender assembly into the fuel tank. CAUTION INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO THE PARTS CATALOG FOR PROPER APPLICATIONS. 6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from acting as an antenna. Be sure ground is secure and protected from corrosion since it is the operating ground for the fuel pump. 7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9573 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9574 OPERATION/DESCRIPTION/TIME DEALER CODING OASIS CODES: 205000, 207000, 404000, 702000, 702300 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Page 9575 Speaker: Specifications Radio speaker screws ......................................................................................................................... .......................................................... 3 N.m (27 Lb-In) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Page 9576 Speaker: Description and Operation On regular cab vehicles: - The rear radio speakers are located behind the rear corner trim panel below the front safety belt retractor and tongue. - The front radio speakers are located behind the front door trim panel. On SuperCab vehicles: - The rear radio speakers are located behind the rear door trim panels in the rear doors. - The front radio speakers are located behind the front door trim panels. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Page 9577 Speaker: Service and Repair Door Mounted Speaker REMOVAL 1. Remove the door trim panels. 2. Remove the speakers. 1 Remove the screws. 2 Disconnect the electrical connectors. 3 Remove the speakers. INSTALLATION 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Service and Repair Tape Player: Service and Repair Cleaning and Inspection 1. For best performance, it is recommended that the tape player be cleaned once for every 10 to 12 hours of playing time. The tape player should be cleaned using a Ford tape player cleaning cartridge, available at your Ford or Lincoln-Mercury Dealer. The use of other cleaning products is not recommended, as these products could cause damage to the player or cassette tapes. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations Accessory Delay Relay: Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 9586 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 9587 Accessory Delay Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 9588 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module > Page 9593 Alarm Module: Diagrams Remote Anti-Theft Personality Module Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module > Page 9594 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Module Replacement Alarm Module: Service and Repair Module Replacement REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the ignition switch lock cylinder. 1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2 Insert a punch in the access hole of the steering column and press the release tab while pushing out the ignition switch lock cylinder. 3. Unscrew and remove the tilt wheel handle and shank. 4. Remove the instrument panel steering column cover. 5. Remove the upper and lower steering column shrouds. 1 Remove the screws. 2 Remove the lower steering column shroud. 3 Remove the upper steering column shroud. NOTE: The steering wheel has been removed for clarity. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Module Replacement > Page 9597 6. Remove the anti-theft transceiver module. 1 Remove the screw from the bottom of the transceiver module. 2 Disconnect the electrical connector and remove the module. NOTE: Only apply pressure or leverage below the key cylinder lower rib. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Module Replacement > Page 9598 Alarm Module: Service and Repair Remote Anti-Theft Personality Module REMOVAL 1. Disconnect the battery ground cable. CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the LH front door scuff plate. 3. Remove the LH cowl side trim panel. 4. Disconnect the two Remote Anti-Theft Personality (RAP) module electrical connectors. 1 Disconnect C257. 2 Disconnect C256. NOTE: If C256 is disconnected first, an inadvertent IGNTAM alarm event (AL__EVT) will be stored and the alarm will sound. The alarm must be disarmed by the remote unlock button or a key in the door lock cylinder to UNLOCK. To avoid this condition, disconnect (1) C257 before (2) C256 and reconnect (2) C256 before (1) C257. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Service and Repair > Module Replacement > Page 9599 5. Remove the RAP module nuts and the RAP module. INSTALLATION 1. To install, reverse the removal procedure. NOTE When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. - To avoid inadvertent alarm activation, reconnect C256 first. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Technical Service Bulletins > Customer Interest for General Module: > 99-21-3 > Oct > 99 > Autolock System - Functions Not Operating Properly General Module: Customer Interest Autolock System - Functions Not Operating Properly Article No 99-21-3 10/18/99 AUTO-LOCK - AUTO-LOCK FUNCTIONS NOT OPERATING PROPERLY - VEHICLES BUILT FROM 6/3/1999 THROUGH 6/8/1999 FORD: 1999 F-150, F-250 LD ISSUE The Auto-Lock Functions may not be operating properly. This may consist of the relock function inoperative after initial lock or door locks engaging with door open/ajar. Additionally, the double chirp horn alert which indicates door ajar does not operate when the key fob lock button is actuated. These may be due to the door ajar circuit missing from the Generic Electronic Module (GEM) to the Remote Anti-theft Personality (RAP) Module. ACTION Install missing Circuit 999. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the instrument panel fuse junction panel. Refer to the 1999 F-150/250 Workshop Manual, Page 419-10-3, Removal and Installation - Module GEM/CTM. 2. Disengage pin locking bar on C240 connector (GEM 16-way connector) and insert Circuit 999 (LB/W, jumper XL3Z-14A411-BA) into connector location Pin # 3 (Figure 1). Reinsert locking bar. 3. Remove left scuff plate and kick panel to access the C247F connector. 4. Route jumper wire along the -14401- harness to C247F connector at the -14A005- harness in left kick panel area. 5. Remove C247F connector (gray 16-way connector) from finger bracket and disconnect from mating connector. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Technical Service Bulletins > Customer Interest for General Module: > 99-21-3 > Oct > 99 > Autolock System - Functions Not Operating Properly > Page 9608 6. Disengage and remove red locking spacer from C247F connector and insert Circuit 999 (LB/W, jumper XL3Z-14A411-BA) into connector location Pin # 3 (Figure 2). Reinsert red locking spacer. Spot tape jumper circuit along -14401-harness to the -14A005- harness. 7. Reconnect -14401- connector to -14A005- 16-way connector and reattach to finger bracket. 8. Reinstall left kick panel and scuff plate. 9. Reassemble instrument panel fuse junction panel and GEM per Workshop Manual, Page 419-10-3. 10. To functionally test repair, ensure either the driver/passenger door is open, press lock button on key fob twice, and listen for two horn chirps. 11. Connect New Generation Star (NGS) Tester to the vehicle and clear all codes. Then test RAP and GEM modules for any system failure induced during the repair procedure. PART NUMBER PART NAME XL3Z-14A411-BA Jumper Harness OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 992103A Repair Door Ajar Circuit 0.9 Hrs. DEALER CODING CONDITION BASIC PART NO. CODE 14A411 39 OASIS CODES: 112000, 203000, 203200, 205000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for General Module: > 99-21-3 > Oct > 99 > Autolock System - Functions Not Operating Properly General Module: All Technical Service Bulletins Autolock System - Functions Not Operating Properly Article No 99-21-3 10/18/99 AUTO-LOCK - AUTO-LOCK FUNCTIONS NOT OPERATING PROPERLY - VEHICLES BUILT FROM 6/3/1999 THROUGH 6/8/1999 FORD: 1999 F-150, F-250 LD ISSUE The Auto-Lock Functions may not be operating properly. This may consist of the relock function inoperative after initial lock or door locks engaging with door open/ajar. Additionally, the double chirp horn alert which indicates door ajar does not operate when the key fob lock button is actuated. These may be due to the door ajar circuit missing from the Generic Electronic Module (GEM) to the Remote Anti-theft Personality (RAP) Module. ACTION Install missing Circuit 999. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the instrument panel fuse junction panel. Refer to the 1999 F-150/250 Workshop Manual, Page 419-10-3, Removal and Installation - Module GEM/CTM. 2. Disengage pin locking bar on C240 connector (GEM 16-way connector) and insert Circuit 999 (LB/W, jumper XL3Z-14A411-BA) into connector location Pin # 3 (Figure 1). Reinsert locking bar. 3. Remove left scuff plate and kick panel to access the C247F connector. 4. Route jumper wire along the -14401- harness to C247F connector at the -14A005- harness in left kick panel area. 5. Remove C247F connector (gray 16-way connector) from finger bracket and disconnect from mating connector. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for General Module: > 99-21-3 > Oct > 99 > Autolock System - Functions Not Operating Properly > Page 9614 6. Disengage and remove red locking spacer from C247F connector and insert Circuit 999 (LB/W, jumper XL3Z-14A411-BA) into connector location Pin # 3 (Figure 2). Reinsert red locking spacer. Spot tape jumper circuit along -14401-harness to the -14A005- harness. 7. Reconnect -14401- connector to -14A005- 16-way connector and reattach to finger bracket. 8. Reinstall left kick panel and scuff plate. 9. Reassemble instrument panel fuse junction panel and GEM per Workshop Manual, Page 419-10-3. 10. To functionally test repair, ensure either the driver/passenger door is open, press lock button on key fob twice, and listen for two horn chirps. 11. Connect New Generation Star (NGS) Tester to the vehicle and clear all codes. Then test RAP and GEM modules for any system failure induced during the repair procedure. PART NUMBER PART NAME XL3Z-14A411-BA Jumper Harness OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 992103A Repair Door Ajar Circuit 0.9 Hrs. DEALER CODING CONDITION BASIC PART NO. CODE 14A411 39 OASIS CODES: 112000, 203000, 203200, 205000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions General Module: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9617 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9618 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9619 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9620 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9621 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9622 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9623 General Module: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9624 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9625 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9626 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9627 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9628 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9629 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9630 General Module: Connector Views Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9631 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9632 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9633 General Module: Electrical Diagrams Diagram 59-1 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9634 Diagram 59-2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9635 Diagram 59-3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9636 Diagram 59-4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Page 9637 General Module: Description and Operation NOTE - Each vehicle has either a Generic Electronic Module (GEM) or Central Timer Module (CTM). The difference in functionality is defined in the GEM/CTM Feature Matrix. - The GEM/CTM inputs and outputs are designed to withstand continuous exposure to a short circuit to ground or battery voltage without being damaged. The multifunction modules consist of the following: - Remote Anti-Theft Personality (RAP) module - Central Timer Module (CTM) with diagnostic connector - Generic Electronic Module (GEM) GEM/CTM Feature Matrix Ignition Switch Positions The position of the ignition switch is very important to proper GEM/CTM operation. Often times, erratic or unexpected operation can be traced to problems on these GEM/CTM inputs. The following is a brief description of five ignition switch positions. When the ignition switch is in the RUN position, battery voltage should be present at the GEM/CTM RUN and RUN/ACC input terminals. When the ignition switch is in the ACC position, battery voltage should be present at the GEM/CTM RUN/ACC input terminal only. When the ignition switch is in the START position, battery voltage should be present at the GEM/CTM start/clutch depressed input. The GEM module does not have an OFF or LOCK switch state input. The GEM will assume the OFF or LOCK position when there are no RUN, ACC, or START signals present. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Page 9638 General Module: Service and Repair Generic Electronic (GEM)/Central Timer (CTM) Module REMOVAL 1. Disconnect the battery ground cable. CAUTION Prior to removal of the module, it is necessary to upload module configuration information to New Generation STAR (NGS) Tester. This information needs to be downloaded into the new module once installed. - Electronic modules are sensitive to electrical charges. If exposed to these charges, damage may result. 2. Remove the steering column cover. 3. Remove the (A) bulkhead electrical connectors from the (B) instrument panel fuse junction panel. 4. Remove the (A) instrument panel fuse junction panel bolts and remove the (B) interior fuse junction panel nuts. 5. Disconnect the (A) Generic Electronic Module (GEM)/Central Timer Module (CTM) electrical connectors from the (B) GEM/CTM. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > General Module > Component Information > Diagrams > Page 9639 6. Remove the screws and the GEM/CTM. INSTALLATION 1. To install, reverse the removal procedure. - Check for proper operation. CAUTION: Once the new module is installed, it is necessary to download the module configuration information from the New Generation STAR (NGS) Tester into the new module. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams Keyless Entry Module: Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Diagrams > Page 9643 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Locations > Component Locations Trailer Connector: Component Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Locations > Component Locations > Page 9649 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Locations > Component Locations > Page 9650 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Locations > Component Locations > Page 9651 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Locations > Component Locations > Page 9652 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Locations > Component Locations > Page 9653 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Locations > Component Locations > Page 9654 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Locations > Component Locations > Page 9655 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Locations > Component Locations > Page 9656 Trailer Connector: Connector Locations C100-C115 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Locations > Component Locations > Page 9657 C116-C141 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Locations > Component Locations > Page 9658 C142-C172 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Locations > Component Locations > Page 9659 C174-C199 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Locations > Component Locations > Page 9660 C200-C227 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Locations > Component Locations > Page 9661 C228-C259 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Locations > Component Locations > Page 9662 C260-C406 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Locations > Component Locations > Page 9663 C407-C510 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Locations > Component Locations > Page 9664 C511-C1022 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Locations > Component Locations > Page 9665 G100-G400 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Locations > Component Locations > Page 9666 Trailer Connector: Splice Locations S100 ............................................................................................ Engine control sensor harness, in Take Out (T/O) to Powertrain Control Module (PCM) S101 .................................................................................................................................................... ........... Engine control sensor harness, in T/O to PCM S102 ...................................................................................................................................... Engine control sensor harness, near T/O to starter motor relay S104 ............................................................................................................................................ Engine control sensor harness, near T/O to right headlamp S105 ....................................................................................................................................... Engine control sensor harness, in T/O to battery junction box S106 ........................................................................................................................................................... Engine control sensor harness, near T/O to G104 S108 ....................................................................................................................................... Engine control sensor harness, in T/O to battery junction box S109 ....................................................................................................................................................... Engine control sensor harness, near T/O to C150M S112 .................................................................................................................................... Engine control sensor harness, near T/O to battery junction box S113 .................................................................................................................................... Engine control sensor harness, near T/O to battery junction box S114 ............................................................................................................................................. Engine control sensor harness, near T/O to left headlamp S115 ....................................................................................................................................................... Engine control sensor harness, near T/O to C150M S116 ....................................................................................................................................................... Engine control sensor harness, near T/O to C160M S117 (4.2L) ........................................................................................................................................ Fuel charge harness, near T/O to idle air control valve S117 (4.6L, 5.4L) ...................................................................................................................................................... Fuel charge harness, near T/O to C120 S118 ......................................................................................................................................... Fuel charge harness, near T/O to radio noise capacitor C114 S119 ......................................................................................................................................... Fuel charge harness, near T/O to radio noise capacitor C115 S120 .......................................................................................................................................................... Engine control sensor harness, In T/O to C16OM S125 ............................................................................................................................... Heater blower motor feed harness, in T/O to blower motor resistor S126 ............................................................................................................. Engine control sensor harness, near T/O to A/C clutch cycling pressure switch S127 .............................................................................................................................. Engine control sensor harness, near T/O to windshield wiper motor S129 (4.2L) ................................................................................................................................... Fuel charge harness, between takeout for C126 and C123 S129 (4.6L, 5.4L) ....................................................................................................................................... Fuel charge harness, near T/O to coil on plug #3 S130 .......................................................................................................................................................... Engine control sensor harness, in T/O to C12OM S131 (4.2L)....................................................................................................... Fuel charge harness, near T/O to intake manifold runner control monitor #1 S131 (4.6L, 5.4L) ....................................................................................................................................... Fuel charge harness, near T/O to coil on plug #7 S135 (4.2L)................................................................................................................................................. Fuel charge harness, near T/O to fuel injector #4 S135 (4.6L, 5.4L)........................................................................................................................................ Fuel charge harness, near T/O to fuel injector #8 S136 (4.2L) ................................................................................................................................................ Fuel charge harness, near T/O to fuel injector #2 S136 (4.6L)........................................................................................................................................ Fuel charge harness, near T/O to C131 fuel injector #7 S136 (5.4L).................................................................................................................................................. Fuel charge harness, near T/O to coil on plug #4 S137 ...................................................................................................................................... Engine control sensor harness, near T/O to starter motor relay S138 ........................................................................ ....................................................................................... Engine control sensor harness, in T/O to C139 S139 ........................................................................................................................................................... Engine control sensor harness, in T/O to C158M S140 ................................................................................................................................. Reversing lamp switch to rear lamp feed harness, in T/O to C172 S141 ................................................................................................................................. Reversing lamp switch to rear lamp feed harness, in T/O to C172 S142 ...................................................................................................................................... Engine control sensor harness, near T/O to starter motor relay S143 .............................................................................................................................. Engine control sensor harness, near T/O to windshield wiper motor S145 ................................................................. .............................................................................................. Engine control sensor harness, in T/O to horns S146 ........................................................................................................................................................... Engine control sensor harness, near T/O to C159 S147 ................................................................................................................................................... Engine control sensor harness, in T/O to left fog lamp S148 ....................................................................................................................................................... Engine control sensor harness, near T/O to C148M S149 ........................................................................................................................................................... Engine control sensor harness, in T/O to C148M S150 ...................................................................... ......................................................................................... Engine control sensor harness, in T/O to C160 S153 ........................................................................................................................................... .............................. Fuel charge harness, near T/O to C120F S154 ................................................... ...................................................................................................................... Fuel charge harness, near T/O to C119F S155 ............................................................................................................................................ Engine control sensor harness, near T/O to in-line C158M S156 .............................................................................................................................................. Engine control sensor harness, near T/O to in-line C196F S157 .............................................................................................................................................. Engine control sensor harness, near T/O to in-line C196F S159 ........................................................................................................................ Engine control sensor harness, in T/O to C165 windshield wiper motor S160 ............................................................................................................................................ Engine control sensor harness, near T/O to in-line C158M S161 ........................................................................................................................................................... Fuel charge harness, near T/O to fuel injector #3 S162 ........................................................................................................................................................... Fuel charge harness, near T/O to fuel injector #7 S163 ............................................................................................................. Engine control sensor harness, near T/O to A/C clutch cycling pressure switch S170 ................................................................................ Engine control sensor harness, near T/O to 4 Wheel Anti-Lock Brake System (4WABS) module S198 ...................................................................................................................................... Engine control sensor harness, near T/O to starter motor relay S199 ........................................................................ ................................................................................................... Fuel charge harness, near T/O to C120 S200 ........................................................................................................................................... .......................................... Main harness, near T/O to C210 S201 .................................................................................................................... Main harness, near T/O to rear Anti-Lock Brake System (RABS) module S202 ........................................................................................................................................................ Main harness, in T/O to blower/flasher relay block S203 .................................................................... .............................................................................................. Main harness, near T/O to passenger air bag S204 ........................................................................................................................................ ......................... Main harness, near T/O to instrument cluster S205 .................................................. ..................................................................................................................... Main harness, near T/O to RABS module Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Locations > Component Locations > Page 9667 S206 .................................................................................................................................................... ..................................... Main harness, in T/O to C224 S207 .............................................................................................................................................................. Main harness, near T/O to central junction box S208 ......................................................................... ............................................................................................................ Main harness, near T/O to G202 S209 .......................................................................................................................................... ........................................... Main harness, near T/O to G202 S210 ........................................................................................................................................................... Radio speaker jumper harness, near T/O to radio S211 ..................................................................... ............................................................................................ Main harness, near T/O to instrument cluster S212 ......................................................................................................................................... ............................... Main harness, near T/O to in-line C253F S213 ........................................................................................................................................................... Main harness, in T/O to transfer case shift relays S214 ...................................................................... .................................................................................................. Main harness, near T/O to in-line C253F S215 ........................................................................................................................................ .................................. Main harness, in T/O to ignition switch S216 ............................................................................................................................................... Body main harness, near T/O to C254 park brake switch S217 ................................................................... ....................................................................................................... Main harness, in T/O to RABS module S218 ....................................................................................................................................... .............................................. Main harness, near T/O to C242 S219 ................................................. ...................................................................................................................... Main harness, near T/O to RABS module S220 ......................................................................................................................................................... Body main harness, near T/O to park brake switch S221 ................................................................... .................................................................................................................. Main harness, near T/O to C243 S222 ........................................................................................................................................... ...................... Main harness, near T/O to instrument cluster S223 ..................................................... ............................................................................................................ Main harness, near T/O to instrument cluster S224 ....................................................................................................................... .......................................... Main harness, near T/O to instrument cluster S225 ................................. ................................................................................................................................ Main harness, near T/O to instrument cluster S227 ......................................................................................................................................... Main harness, in T/O to Clutch Pedal Position (CPP) switch S228 .............................................................. .................................................................................................... Main harness, in T/O to central junction box S229 ................................................................................................................................ ................................. Main harness, near T/O to instrument cluster S231 .......................................... ....................................................................................................................... Main harness, near T/O to instrument cluster S232 ................................................................................................................... .............................................. Main harness, near T/O to instrument cluster S233 ............................. ............................................................................................................................................................ Main harness, in T/O to C225 S234 ........................................................................................................... Body main harness, near T/O to Remote Anti-Theft Personality (RAP) module S235 ........................................................................ ........................................................................................ Body main harness, near T/O to RAP module S236 ....................................................................................................................................... .......................... Main harness, near T/O to instrument cluster S237 ................................................. .................................................................................................................................... Main harness, near T/O to C243 S238 ................................................................................................................................ Main harness, in T/O to C239 Generic Electronic Module (GEM) S239 .................................................................................................................................................... ..................... Body main harness, near T/O to C206M S240 .............................................................................................................................................................. Main harness, near T/O to ashtray illumination S241 .......................................................................... ........................................................................................ Main harness, near T/O to passenger air bag S242 ............................................................................................................................................. .............................. Main harness, near T/O to CPP switch S243 ....................................................... .................................................................................................................. Body main harness, near T/O to C206M S244 ............................................................................................................................. ...................................... Main harness, near T/O to main light switch S245 ....................................... ........................................................................................................................... Main harness, near T/O to passenger air bag S246 ........................................................................................................... ............................................................. Main harness, near T/O to in-line C159F S247 ..................... ................................................................................................................................................... Main harness, near T/O to in-line C159F S248 ......................................................................................................................................................... Body main harness, near T/O to park brake switch S251 ................................................................... ...................................................................................................... Body main harness, near T/O to C206M S252 ........................................................................................................................................ ............................................... Main harness, in T/O to C265F S253 .................................................. ................................................................................................................... Radio amplifier harness, near T/O to C265 S254 .......................................................................................................................................................... Radio amplifier harness, near T/O to CD changer S265 ..................................................................... ................................................................................................................ Main harness, near T/O to C242 S268 ........................................................................................................................................... ................................ Main harness, near T/O to C240 GEM S289 ...................................................... .................................................................................................................. Main harness, near T/O to in-line C270F S291 .............................................................................................................................. ......................................... Main harness, near T/O to RABS module S294 .................................................................................................................................................... Main harness, near T/O to RABS data link connector S297 ........................................................................ ......................................................................................... Main harness, near T/O to instrument cluster S300 .................................................................................................................................. Seat belt retractor switch right harness, near T/O to interior lamp S301 ................................................................................................................................. Fuel tank sender harness, near T/O to fuel tank solenoid valve #2 S302 ................................................................................................................................. Fuel tank sender harness, near T/O to fuel tank solenoid valve #2 S303 ....................................................................... ............................................................................................ Fuel tank sender harness, near T/O to C316 S304 ................................................................................................................................... Seat belt retractor switch harness, near T/O to right rear speaker S400 ...................................................................................................................................................... Rear lamp harness, near T/O to fuel pump assembly S401 .......................................................................................................................................................... Rear lamp connector harness, near T/O to C403F S403 .......................................................................................................................................................... Rear lamp connector harness, near T/O to C403F S405 .................................................................................................................................... In rear lamp harness, near T/O to C404 left stop/park/turn lamp S409 ......................................................................................................................................................... Rear lamp harness, near T/O to fuel pump module S410 ......................................................................................................................................................... Rear lamp harness, near T/O to fuel pump module S411 ........................................................................................................................................... Rear lamp harness, in T/O to C911 high mounted stoplamp S500 ......................................................................................................................................... Body main harness, near T/O to left power door lock switch S501 .................................................................................................................................................. Body main harness, near T/O to left door lock actuator Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Locations > Component Locations > Page 9668 S503 ............................................................................................................................................. Body main harness, near T/O to left power window motor S600 .......................................................................................................................................... Body main harness, near T/O to right power window switch S911 ......................................................................................................................................... Rear high mounted lamp harness, near T/O to in-line C416F S1001 .................................................................. ........................................................................................................... Battery harness, near T/O to battery S1002 ...................................................................................................................................... ....................................... Battery harness, near T/O to battery S1003 .................................................................................................................................. Engine control sensor harness, near T/O to battery junction box Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9671 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9672 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9673 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9674 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9675 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9676 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9677 Trailer Connector: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9678 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9679 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9680 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9681 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9682 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9683 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9684 Trailer Connector: Connector Views Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9685 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9686 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9687 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9688 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9689 Trailer Connector: Electrical Diagrams Diagram 95-1 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9690 Diagram 95-2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9691 Diagram 95-3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Testing and Inspection > Flow of Diagnosis Trailer Connector: Flow of Diagnosis 1. Verify the customer concern by operating the trailer towing package. 2. Visually inspect for the following obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Battery Junction Box (BJB) Fuse 5 (20A) ^ BJB Fuse 19 (10A) ^ BJB Fuse 20 (10A) ^ BJB Fuse 101 (30A) ^ BJB Fuse 108 (30A) ^ Central Junction Box (CJB) Fuse 23 (10A) ^ CJB Fuse 13 (10A) ^ Corroded/loose connector(s) ^ Loose/broken wire(s) ^ Failed bulb(s) 3. If the concern is not visually evident, determine the symptom and proceed to the Symptom Chart. See: Trailer Lamps/Testing and Inspection/Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9694 Trailer Connector: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the trailer towing package. 2. Visually inspect for the following obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Battery Junction Box (BJB) Fuse 5 (20A) ^ BJB Fuse 19 (10A) ^ BJB Fuse 20 (10A) ^ BJB Fuse 101 (30A) ^ BJB Fuse 108 (30A) ^ Central Junction Box (CJB) Fuse 23 (10A) ^ CJB Fuse 13 (10A) ^ Corroded/loose connector(s) ^ Loose/broken wire(s) ^ Failed bulb(s) 3. If the concern is not visually evident, determine the symptom and proceed to the Symptom Chart. See: Trailer Lamps/Testing and Inspection/Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9695 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9696 Trailer Connector: Pinpoint Tests Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9697 AB1 - AB2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9698 AC1 - AC2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9699 AC3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9700 AD1 - AD2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9701 AD3 Test AE: Trailer Parking Lamps Inoperative Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9702 AE1 - AE2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9703 AE3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9704 AE4 - AE5 Test AF: Trailer Lamp Are Inoperative-Trailer Reversing Lamps Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9705 AF1 - AF2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9706 AF3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9707 AF4 - AF5 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9708 AG1 - AG2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9709 AG3 - AG4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9710 AH1 - AH2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9711 AH3 - AH5 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector > Component Information > Testing and Inspection > Page 9712 73 Digital Multimeter Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Locations > Component Locations Trailer Lamps: Component Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Locations > Component Locations > Page 9717 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Locations > Component Locations > Page 9718 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Locations > Component Locations > Page 9719 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Locations > Component Locations > Page 9720 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Locations > Component Locations > Page 9721 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Locations > Component Locations > Page 9722 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Locations > Component Locations > Page 9723 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Locations > Component Locations > Page 9724 Trailer Lamps: Connector Locations C100-C115 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Locations > Component Locations > Page 9725 C116-C141 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Locations > Component Locations > Page 9726 C142-C172 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Locations > Component Locations > Page 9727 C174-C199 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Locations > Component Locations > Page 9728 C200-C227 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Locations > Component Locations > Page 9729 C228-C259 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Locations > Component Locations > Page 9730 C260-C406 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Locations > Component Locations > Page 9731 C407-C510 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Locations > Component Locations > Page 9732 C511-C1022 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Locations > Component Locations > Page 9733 G100-G400 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Locations > Component Locations > Page 9734 Trailer Lamps: Splice Locations S100 ............................................................................................ Engine control sensor harness, in Take Out (T/O) to Powertrain Control Module (PCM) S101 .................................................................................................................................................... ........... Engine control sensor harness, in T/O to PCM S102 ...................................................................................................................................... Engine control sensor harness, near T/O to starter motor relay S104 ............................................................................................................................................ Engine control sensor harness, near T/O to right headlamp S105 ....................................................................................................................................... Engine control sensor harness, in T/O to battery junction box S106 ........................................................................................................................................................... Engine control sensor harness, near T/O to G104 S108 ....................................................................................................................................... Engine control sensor harness, in T/O to battery junction box S109 ....................................................................................................................................................... Engine control sensor harness, near T/O to C150M S112 .................................................................................................................................... Engine control sensor harness, near T/O to battery junction box S113 .................................................................................................................................... Engine control sensor harness, near T/O to battery junction box S114 ............................................................................................................................................. Engine control sensor harness, near T/O to left headlamp S115 ....................................................................................................................................................... Engine control sensor harness, near T/O to C150M S116 ....................................................................................................................................................... Engine control sensor harness, near T/O to C160M S117 (4.2L) ........................................................................................................................................ Fuel charge harness, near T/O to idle air control valve S117 (4.6L, 5.4L) ...................................................................................................................................................... Fuel charge harness, near T/O to C120 S118 ......................................................................................................................................... Fuel charge harness, near T/O to radio noise capacitor C114 S119 ......................................................................................................................................... Fuel charge harness, near T/O to radio noise capacitor C115 S120 .......................................................................................................................................................... Engine control sensor harness, In T/O to C16OM S125 ............................................................................................................................... Heater blower motor feed harness, in T/O to blower motor resistor S126 ............................................................................................................. Engine control sensor harness, near T/O to A/C clutch cycling pressure switch S127 .............................................................................................................................. Engine control sensor harness, near T/O to windshield wiper motor S129 (4.2L) ................................................................................................................................... Fuel charge harness, between takeout for C126 and C123 S129 (4.6L, 5.4L) ....................................................................................................................................... Fuel charge harness, near T/O to coil on plug #3 S130 .......................................................................................................................................................... Engine control sensor harness, in T/O to C12OM S131 (4.2L)....................................................................................................... Fuel charge harness, near T/O to intake manifold runner control monitor #1 S131 (4.6L, 5.4L) ....................................................................................................................................... Fuel charge harness, near T/O to coil on plug #7 S135 (4.2L)................................................................................................................................................. Fuel charge harness, near T/O to fuel injector #4 S135 (4.6L, 5.4L)........................................................................................................................................ Fuel charge harness, near T/O to fuel injector #8 S136 (4.2L) ................................................................................................................................................ Fuel charge harness, near T/O to fuel injector #2 S136 (4.6L)........................................................................................................................................ Fuel charge harness, near T/O to C131 fuel injector #7 S136 (5.4L).................................................................................................................................................. Fuel charge harness, near T/O to coil on plug #4 S137 ...................................................................................................................................... Engine control sensor harness, near T/O to starter motor relay S138 ........................................................................ ....................................................................................... Engine control sensor harness, in T/O to C139 S139 ........................................................................................................................................................... Engine control sensor harness, in T/O to C158M S140 ................................................................................................................................. Reversing lamp switch to rear lamp feed harness, in T/O to C172 S141 ................................................................................................................................. Reversing lamp switch to rear lamp feed harness, in T/O to C172 S142 ...................................................................................................................................... Engine control sensor harness, near T/O to starter motor relay S143 .............................................................................................................................. Engine control sensor harness, near T/O to windshield wiper motor S145 ................................................................. .............................................................................................. Engine control sensor harness, in T/O to horns S146 ........................................................................................................................................................... Engine control sensor harness, near T/O to C159 S147 ................................................................................................................................................... Engine control sensor harness, in T/O to left fog lamp S148 ....................................................................................................................................................... Engine control sensor harness, near T/O to C148M S149 ........................................................................................................................................................... Engine control sensor harness, in T/O to C148M S150 ...................................................................... ......................................................................................... Engine control sensor harness, in T/O to C160 S153 ........................................................................................................................................... .............................. Fuel charge harness, near T/O to C120F S154 ................................................... ...................................................................................................................... Fuel charge harness, near T/O to C119F S155 ............................................................................................................................................ Engine control sensor harness, near T/O to in-line C158M S156 .............................................................................................................................................. Engine control sensor harness, near T/O to in-line C196F S157 .............................................................................................................................................. Engine control sensor harness, near T/O to in-line C196F S159 ........................................................................................................................ Engine control sensor harness, in T/O to C165 windshield wiper motor S160 ............................................................................................................................................ Engine control sensor harness, near T/O to in-line C158M S161 ........................................................................................................................................................... Fuel charge harness, near T/O to fuel injector #3 S162 ........................................................................................................................................................... Fuel charge harness, near T/O to fuel injector #7 S163 ............................................................................................................. Engine control sensor harness, near T/O to A/C clutch cycling pressure switch S170 ................................................................................ Engine control sensor harness, near T/O to 4 Wheel Anti-Lock Brake System (4WABS) module S198 ...................................................................................................................................... Engine control sensor harness, near T/O to starter motor relay S199 ........................................................................ ................................................................................................... Fuel charge harness, near T/O to C120 S200 ........................................................................................................................................... .......................................... Main harness, near T/O to C210 S201 .................................................................................................................... Main harness, near T/O to rear Anti-Lock Brake System (RABS) module S202 ........................................................................................................................................................ Main harness, in T/O to blower/flasher relay block S203 .................................................................... .............................................................................................. Main harness, near T/O to passenger air bag S204 ........................................................................................................................................ ......................... Main harness, near T/O to instrument cluster S205 .................................................. ..................................................................................................................... Main harness, near T/O to RABS module Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Locations > Component Locations > Page 9735 S206 .................................................................................................................................................... ..................................... Main harness, in T/O to C224 S207 .............................................................................................................................................................. Main harness, near T/O to central junction box S208 ......................................................................... ............................................................................................................ Main harness, near T/O to G202 S209 .......................................................................................................................................... ........................................... Main harness, near T/O to G202 S210 ........................................................................................................................................................... Radio speaker jumper harness, near T/O to radio S211 ..................................................................... ............................................................................................ Main harness, near T/O to instrument cluster S212 ......................................................................................................................................... ............................... Main harness, near T/O to in-line C253F S213 ........................................................................................................................................................... Main harness, in T/O to transfer case shift relays S214 ...................................................................... .................................................................................................. Main harness, near T/O to in-line C253F S215 ........................................................................................................................................ .................................. Main harness, in T/O to ignition switch S216 ............................................................................................................................................... Body main harness, near T/O to C254 park brake switch S217 ................................................................... ....................................................................................................... Main harness, in T/O to RABS module S218 ....................................................................................................................................... .............................................. Main harness, near T/O to C242 S219 ................................................. ...................................................................................................................... Main harness, near T/O to RABS module S220 ......................................................................................................................................................... Body main harness, near T/O to park brake switch S221 ................................................................... .................................................................................................................. Main harness, near T/O to C243 S222 ........................................................................................................................................... ...................... Main harness, near T/O to instrument cluster S223 ..................................................... ............................................................................................................ Main harness, near T/O to instrument cluster S224 ....................................................................................................................... .......................................... Main harness, near T/O to instrument cluster S225 ................................. ................................................................................................................................ Main harness, near T/O to instrument cluster S227 ......................................................................................................................................... Main harness, in T/O to Clutch Pedal Position (CPP) switch S228 .............................................................. .................................................................................................... Main harness, in T/O to central junction box S229 ................................................................................................................................ ................................. Main harness, near T/O to instrument cluster S231 .......................................... ....................................................................................................................... Main harness, near T/O to instrument cluster S232 ................................................................................................................... .............................................. Main harness, near T/O to instrument cluster S233 ............................. ............................................................................................................................................................ Main harness, in T/O to C225 S234 ........................................................................................................... Body main harness, near T/O to Remote Anti-Theft Personality (RAP) module S235 ........................................................................ ........................................................................................ Body main harness, near T/O to RAP module S236 ....................................................................................................................................... .......................... Main harness, near T/O to instrument cluster S237 ................................................. .................................................................................................................................... Main harness, near T/O to C243 S238 ................................................................................................................................ Main harness, in T/O to C239 Generic Electronic Module (GEM) S239 .................................................................................................................................................... ..................... Body main harness, near T/O to C206M S240 .............................................................................................................................................................. Main harness, near T/O to ashtray illumination S241 .......................................................................... ........................................................................................ Main harness, near T/O to passenger air bag S242 ............................................................................................................................................. .............................. Main harness, near T/O to CPP switch S243 ....................................................... .................................................................................................................. Body main harness, near T/O to C206M S244 ............................................................................................................................. ...................................... Main harness, near T/O to main light switch S245 ....................................... ........................................................................................................................... Main harness, near T/O to passenger air bag S246 ........................................................................................................... ............................................................. Main harness, near T/O to in-line C159F S247 ..................... ................................................................................................................................................... Main harness, near T/O to in-line C159F S248 ......................................................................................................................................................... Body main harness, near T/O to park brake switch S251 ................................................................... ...................................................................................................... Body main harness, near T/O to C206M S252 ........................................................................................................................................ ............................................... Main harness, in T/O to C265F S253 .................................................. ................................................................................................................... Radio amplifier harness, near T/O to C265 S254 .......................................................................................................................................................... Radio amplifier harness, near T/O to CD changer S265 ..................................................................... ................................................................................................................ Main harness, near T/O to C242 S268 ........................................................................................................................................... ................................ Main harness, near T/O to C240 GEM S289 ...................................................... .................................................................................................................. Main harness, near T/O to in-line C270F S291 .............................................................................................................................. ......................................... Main harness, near T/O to RABS module S294 .................................................................................................................................................... Main harness, near T/O to RABS data link connector S297 ........................................................................ ......................................................................................... Main harness, near T/O to instrument cluster S300 .................................................................................................................................. Seat belt retractor switch right harness, near T/O to interior lamp S301 ................................................................................................................................. Fuel tank sender harness, near T/O to fuel tank solenoid valve #2 S302 ................................................................................................................................. Fuel tank sender harness, near T/O to fuel tank solenoid valve #2 S303 ....................................................................... ............................................................................................ Fuel tank sender harness, near T/O to C316 S304 ................................................................................................................................... Seat belt retractor switch harness, near T/O to right rear speaker S400 ...................................................................................................................................................... Rear lamp harness, near T/O to fuel pump assembly S401 .......................................................................................................................................................... Rear lamp connector harness, near T/O to C403F S403 .......................................................................................................................................................... Rear lamp connector harness, near T/O to C403F S405 .................................................................................................................................... In rear lamp harness, near T/O to C404 left stop/park/turn lamp S409 ......................................................................................................................................................... Rear lamp harness, near T/O to fuel pump module S410 ......................................................................................................................................................... Rear lamp harness, near T/O to fuel pump module S411 ........................................................................................................................................... Rear lamp harness, in T/O to C911 high mounted stoplamp S500 ......................................................................................................................................... Body main harness, near T/O to left power door lock switch S501 .................................................................................................................................................. Body main harness, near T/O to left door lock actuator Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Locations > Component Locations > Page 9736 S503 ............................................................................................................................................. Body main harness, near T/O to left power window motor S600 .......................................................................................................................................... Body main harness, near T/O to right power window switch S911 ......................................................................................................................................... Rear high mounted lamp harness, near T/O to in-line C416F S1001 .................................................................. ........................................................................................................... Battery harness, near T/O to battery S1002 ...................................................................................................................................... ....................................... Battery harness, near T/O to battery S1003 .................................................................................................................................. Engine control sensor harness, near T/O to battery junction box Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > C232 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > C232 > Page 9739 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > C232 > Page 9740 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > C232 > Page 9741 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > C232 > Page 9742 Trailer Lamps: Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > C232 > Page 9743 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > C232 > Page 9744 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > C232 > Page 9745 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > C232 > Page 9746 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Diagrams > Page 9747 Trailer Lamps: Description and Operation Vehicles equipped with the trailer towing package have the additions to support the trailer wiring: ^ A set of relays in the engine compartment and connector on the rear lamp wiring, located in the rear bumper area. ^ Trailer feed wiring is supplied with the vehicle and installed at the time of pre-delivery. ^ Vehicles are equipped with a wiring feed, located under the instrument panel, for a trailer brake control unit. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis Trailer Lamps: Flow of Diagnosis 1. Verify the customer concern by operating the trailer towing package. 2. Visually inspect for the following obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Battery Junction Box (BJB) Fuse 5 (20A) ^ BJB Fuse 19 (10A) ^ BJB Fuse 20 (10A) ^ BJB Fuse 101 (30A) ^ BJB Fuse 108 (30A) ^ Central Junction Box (CJB) Fuse 23 (10A) ^ CJB Fuse 13 (10A) ^ Corroded/loose connector(s) ^ Loose/broken wire(s) ^ Failed bulb(s) 3. If the concern is not visually evident, determine the symptom and proceed to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9750 Trailer Lamps: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the trailer towing package. 2. Visually inspect for the following obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Battery Junction Box (BJB) Fuse 5 (20A) ^ BJB Fuse 19 (10A) ^ BJB Fuse 20 (10A) ^ BJB Fuse 101 (30A) ^ BJB Fuse 108 (30A) ^ Central Junction Box (CJB) Fuse 23 (10A) ^ CJB Fuse 13 (10A) ^ Corroded/loose connector(s) ^ Loose/broken wire(s) ^ Failed bulb(s) 3. If the concern is not visually evident, determine the symptom and proceed to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9751 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9752 Trailer Lamps: Pinpoint Tests Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9753 AB1 - AB2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9754 AC1 - AC2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9755 AC3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9756 AD1 - AD2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9757 AD3 AE Trailer Parking Lamps Inop Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9758 AE1 - AE2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9759 AE3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9760 AE4 - AE5 AF Trailer Lamp Are Inop-Trailer Reversing Lamps Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9761 AF1 - AF2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9762 AF3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9763 AF4 - AF5 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9764 AG1 - AG2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9765 AG3 - AG4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9766 AH1 - AH2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9767 AH3 - AH5 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9768 73 Digital Multimeter Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Regular Production Option Relay Block Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Regular Production Option Relay Block > Page 9773 Trailer Lighting Relay: Locations Trailer Running Lamps Relay Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Regular Production Option Relay Block > Page 9774 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Regular Production Option Relay Block > Page 9775 Trailer Lighting Relay: Locations Trailer Tow Battery Charge Relay Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Regular Production Option Relay Block > Page 9776 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Regular Production Option Relay Block > Page 9777 Trailer Lighting Relay: Locations Trailer Tow Reversing Lamp Relay Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Regular Production Option Relay Block > Page 9778 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Page 9779 Trailer Lighting Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations > Page 9780 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Locations > Component Locations Trailer Connector: Component Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Locations > Component Locations > Page 9785 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Locations > Component Locations > Page 9786 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Locations > Component Locations > Page 9787 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Locations > Component Locations > Page 9788 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Locations > Component Locations > Page 9789 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Locations > Component Locations > Page 9790 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Locations > Component Locations > Page 9791 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Locations > Component Locations > Page 9792 Trailer Connector: Connector Locations C100-C115 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Locations > Component Locations > Page 9793 C116-C141 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Locations > Component Locations > Page 9794 C142-C172 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Locations > Component Locations > Page 9795 C174-C199 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Locations > Component Locations > Page 9796 C200-C227 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Locations > Component Locations > Page 9797 C228-C259 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Locations > Component Locations > Page 9798 C260-C406 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Locations > Component Locations > Page 9799 C407-C510 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Locations > Component Locations > Page 9800 C511-C1022 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Locations > Component Locations > Page 9801 G100-G400 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Locations > Component Locations > Page 9802 Trailer Connector: Splice Locations S100 ............................................................................................ Engine control sensor harness, in Take Out (T/O) to Powertrain Control Module (PCM) S101 .................................................................................................................................................... ........... Engine control sensor harness, in T/O to PCM S102 ...................................................................................................................................... Engine control sensor harness, near T/O to starter motor relay S104 ............................................................................................................................................ Engine control sensor harness, near T/O to right headlamp S105 ....................................................................................................................................... Engine control sensor harness, in T/O to battery junction box S106 ........................................................................................................................................................... Engine control sensor harness, near T/O to G104 S108 ....................................................................................................................................... Engine control sensor harness, in T/O to battery junction box S109 ....................................................................................................................................................... Engine control sensor harness, near T/O to C150M S112 .................................................................................................................................... Engine control sensor harness, near T/O to battery junction box S113 .................................................................................................................................... Engine control sensor harness, near T/O to battery junction box S114 ............................................................................................................................................. Engine control sensor harness, near T/O to left headlamp S115 ....................................................................................................................................................... Engine control sensor harness, near T/O to C150M S116 ....................................................................................................................................................... Engine control sensor harness, near T/O to C160M S117 (4.2L) ........................................................................................................................................ Fuel charge harness, near T/O to idle air control valve S117 (4.6L, 5.4L) ...................................................................................................................................................... Fuel charge harness, near T/O to C120 S118 ......................................................................................................................................... Fuel charge harness, near T/O to radio noise capacitor C114 S119 ......................................................................................................................................... Fuel charge harness, near T/O to radio noise capacitor C115 S120 .......................................................................................................................................................... Engine control sensor harness, In T/O to C16OM S125 ............................................................................................................................... Heater blower motor feed harness, in T/O to blower motor resistor S126 ............................................................................................................. Engine control sensor harness, near T/O to A/C clutch cycling pressure switch S127 .............................................................................................................................. Engine control sensor harness, near T/O to windshield wiper motor S129 (4.2L) ................................................................................................................................... Fuel charge harness, between takeout for C126 and C123 S129 (4.6L, 5.4L) ....................................................................................................................................... Fuel charge harness, near T/O to coil on plug #3 S130 .......................................................................................................................................................... Engine control sensor harness, in T/O to C12OM S131 (4.2L)....................................................................................................... Fuel charge harness, near T/O to intake manifold runner control monitor #1 S131 (4.6L, 5.4L) ....................................................................................................................................... Fuel charge harness, near T/O to coil on plug #7 S135 (4.2L)................................................................................................................................................. Fuel charge harness, near T/O to fuel injector #4 S135 (4.6L, 5.4L)........................................................................................................................................ Fuel charge harness, near T/O to fuel injector #8 S136 (4.2L) ................................................................................................................................................ Fuel charge harness, near T/O to fuel injector #2 S136 (4.6L)........................................................................................................................................ Fuel charge harness, near T/O to C131 fuel injector #7 S136 (5.4L).................................................................................................................................................. Fuel charge harness, near T/O to coil on plug #4 S137 ...................................................................................................................................... Engine control sensor harness, near T/O to starter motor relay S138 ........................................................................ ....................................................................................... Engine control sensor harness, in T/O to C139 S139 ........................................................................................................................................................... Engine control sensor harness, in T/O to C158M S140 ................................................................................................................................. Reversing lamp switch to rear lamp feed harness, in T/O to C172 S141 ................................................................................................................................. Reversing lamp switch to rear lamp feed harness, in T/O to C172 S142 ...................................................................................................................................... Engine control sensor harness, near T/O to starter motor relay S143 .............................................................................................................................. Engine control sensor harness, near T/O to windshield wiper motor S145 ................................................................. .............................................................................................. Engine control sensor harness, in T/O to horns S146 ........................................................................................................................................................... Engine control sensor harness, near T/O to C159 S147 ................................................................................................................................................... Engine control sensor harness, in T/O to left fog lamp S148 ....................................................................................................................................................... Engine control sensor harness, near T/O to C148M S149 ........................................................................................................................................................... Engine control sensor harness, in T/O to C148M S150 ...................................................................... ......................................................................................... Engine control sensor harness, in T/O to C160 S153 ........................................................................................................................................... .............................. Fuel charge harness, near T/O to C120F S154 ................................................... ...................................................................................................................... Fuel charge harness, near T/O to C119F S155 ............................................................................................................................................ Engine control sensor harness, near T/O to in-line C158M S156 .............................................................................................................................................. Engine control sensor harness, near T/O to in-line C196F S157 .............................................................................................................................................. Engine control sensor harness, near T/O to in-line C196F S159 ........................................................................................................................ Engine control sensor harness, in T/O to C165 windshield wiper motor S160 ............................................................................................................................................ Engine control sensor harness, near T/O to in-line C158M S161 ........................................................................................................................................................... Fuel charge harness, near T/O to fuel injector #3 S162 ........................................................................................................................................................... Fuel charge harness, near T/O to fuel injector #7 S163 ............................................................................................................. Engine control sensor harness, near T/O to A/C clutch cycling pressure switch S170 ................................................................................ Engine control sensor harness, near T/O to 4 Wheel Anti-Lock Brake System (4WABS) module S198 ...................................................................................................................................... Engine control sensor harness, near T/O to starter motor relay S199 ........................................................................ ................................................................................................... Fuel charge harness, near T/O to C120 S200 ........................................................................................................................................... .......................................... Main harness, near T/O to C210 S201 .................................................................................................................... Main harness, near T/O to rear Anti-Lock Brake System (RABS) module S202 ........................................................................................................................................................ Main harness, in T/O to blower/flasher relay block S203 .................................................................... .............................................................................................. Main harness, near T/O to passenger air bag S204 ........................................................................................................................................ ......................... Main harness, near T/O to instrument cluster S205 .................................................. ..................................................................................................................... Main harness, near T/O to RABS module Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Locations > Component Locations > Page 9803 S206 .................................................................................................................................................... ..................................... Main harness, in T/O to C224 S207 .............................................................................................................................................................. Main harness, near T/O to central junction box S208 ......................................................................... ............................................................................................................ Main harness, near T/O to G202 S209 .......................................................................................................................................... ........................................... Main harness, near T/O to G202 S210 ........................................................................................................................................................... Radio speaker jumper harness, near T/O to radio S211 ..................................................................... ............................................................................................ Main harness, near T/O to instrument cluster S212 ......................................................................................................................................... ............................... Main harness, near T/O to in-line C253F S213 ........................................................................................................................................................... Main harness, in T/O to transfer case shift relays S214 ...................................................................... .................................................................................................. Main harness, near T/O to in-line C253F S215 ........................................................................................................................................ .................................. Main harness, in T/O to ignition switch S216 ............................................................................................................................................... Body main harness, near T/O to C254 park brake switch S217 ................................................................... ....................................................................................................... Main harness, in T/O to RABS module S218 ....................................................................................................................................... .............................................. Main harness, near T/O to C242 S219 ................................................. ...................................................................................................................... Main harness, near T/O to RABS module S220 ......................................................................................................................................................... Body main harness, near T/O to park brake switch S221 ................................................................... .................................................................................................................. Main harness, near T/O to C243 S222 ........................................................................................................................................... ...................... Main harness, near T/O to instrument cluster S223 ..................................................... ............................................................................................................ Main harness, near T/O to instrument cluster S224 ....................................................................................................................... .......................................... Main harness, near T/O to instrument cluster S225 ................................. ................................................................................................................................ Main harness, near T/O to instrument cluster S227 ......................................................................................................................................... Main harness, in T/O to Clutch Pedal Position (CPP) switch S228 .............................................................. .................................................................................................... Main harness, in T/O to central junction box S229 ................................................................................................................................ ................................. Main harness, near T/O to instrument cluster S231 .......................................... ....................................................................................................................... Main harness, near T/O to instrument cluster S232 ................................................................................................................... .............................................. Main harness, near T/O to instrument cluster S233 ............................. ............................................................................................................................................................ Main harness, in T/O to C225 S234 ........................................................................................................... Body main harness, near T/O to Remote Anti-Theft Personality (RAP) module S235 ........................................................................ ........................................................................................ Body main harness, near T/O to RAP module S236 ....................................................................................................................................... .......................... Main harness, near T/O to instrument cluster S237 ................................................. .................................................................................................................................... Main harness, near T/O to C243 S238 ................................................................................................................................ Main harness, in T/O to C239 Generic Electronic Module (GEM) S239 .................................................................................................................................................... ..................... Body main harness, near T/O to C206M S240 .............................................................................................................................................................. Main harness, near T/O to ashtray illumination S241 .......................................................................... ........................................................................................ Main harness, near T/O to passenger air bag S242 ............................................................................................................................................. .............................. Main harness, near T/O to CPP switch S243 ....................................................... .................................................................................................................. Body main harness, near T/O to C206M S244 ............................................................................................................................. ...................................... Main harness, near T/O to main light switch S245 ....................................... ........................................................................................................................... Main harness, near T/O to passenger air bag S246 ........................................................................................................... ............................................................. Main harness, near T/O to in-line C159F S247 ..................... ................................................................................................................................................... Main harness, near T/O to in-line C159F S248 ......................................................................................................................................................... Body main harness, near T/O to park brake switch S251 ................................................................... ...................................................................................................... Body main harness, near T/O to C206M S252 ........................................................................................................................................ ............................................... Main harness, in T/O to C265F S253 .................................................. ................................................................................................................... Radio amplifier harness, near T/O to C265 S254 .......................................................................................................................................................... Radio amplifier harness, near T/O to CD changer S265 ..................................................................... ................................................................................................................ Main harness, near T/O to C242 S268 ........................................................................................................................................... ................................ Main harness, near T/O to C240 GEM S289 ...................................................... .................................................................................................................. Main harness, near T/O to in-line C270F S291 .............................................................................................................................. ......................................... Main harness, near T/O to RABS module S294 .................................................................................................................................................... Main harness, near T/O to RABS data link connector S297 ........................................................................ ......................................................................................... Main harness, near T/O to instrument cluster S300 .................................................................................................................................. Seat belt retractor switch right harness, near T/O to interior lamp S301 ................................................................................................................................. Fuel tank sender harness, near T/O to fuel tank solenoid valve #2 S302 ................................................................................................................................. Fuel tank sender harness, near T/O to fuel tank solenoid valve #2 S303 ....................................................................... ............................................................................................ Fuel tank sender harness, near T/O to C316 S304 ................................................................................................................................... Seat belt retractor switch harness, near T/O to right rear speaker S400 ...................................................................................................................................................... Rear lamp harness, near T/O to fuel pump assembly S401 .......................................................................................................................................................... Rear lamp connector harness, near T/O to C403F S403 .......................................................................................................................................................... Rear lamp connector harness, near T/O to C403F S405 .................................................................................................................................... In rear lamp harness, near T/O to C404 left stop/park/turn lamp S409 ......................................................................................................................................................... Rear lamp harness, near T/O to fuel pump module S410 ......................................................................................................................................................... Rear lamp harness, near T/O to fuel pump module S411 ........................................................................................................................................... Rear lamp harness, in T/O to C911 high mounted stoplamp S500 ......................................................................................................................................... Body main harness, near T/O to left power door lock switch S501 .................................................................................................................................................. Body main harness, near T/O to left door lock actuator Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Locations > Component Locations > Page 9804 S503 ............................................................................................................................................. Body main harness, near T/O to left power window motor S600 .......................................................................................................................................... Body main harness, near T/O to right power window switch S911 ......................................................................................................................................... Rear high mounted lamp harness, near T/O to in-line C416F S1001 .................................................................. ........................................................................................................... Battery harness, near T/O to battery S1002 ...................................................................................................................................... ....................................... Battery harness, near T/O to battery S1003 .................................................................................................................................. Engine control sensor harness, near T/O to battery junction box Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions Trailer Connector: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9807 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9808 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9809 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9810 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9811 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9812 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9813 Trailer Connector: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9814 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9815 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9816 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9817 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9818 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9819 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9820 Trailer Connector: Connector Views Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9821 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9822 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9823 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9824 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9825 Trailer Connector: Electrical Diagrams Diagram 95-1 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9826 Diagram 95-2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams > Diagram Information and Instructions > Page 9827 Diagram 95-3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Testing and Inspection > Flow of Diagnosis Trailer Connector: Flow of Diagnosis 1. Verify the customer concern by operating the trailer towing package. 2. Visually inspect for the following obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Battery Junction Box (BJB) Fuse 5 (20A) ^ BJB Fuse 19 (10A) ^ BJB Fuse 20 (10A) ^ BJB Fuse 101 (30A) ^ BJB Fuse 108 (30A) ^ Central Junction Box (CJB) Fuse 23 (10A) ^ CJB Fuse 13 (10A) ^ Corroded/loose connector(s) ^ Loose/broken wire(s) ^ Failed bulb(s) 3. If the concern is not visually evident, determine the symptom and proceed to the Symptom Chart. See: Towing / Trailer System/Trailer Lamps/Testing and Inspection/Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9830 Trailer Connector: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the trailer towing package. 2. Visually inspect for the following obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Battery Junction Box (BJB) Fuse 5 (20A) ^ BJB Fuse 19 (10A) ^ BJB Fuse 20 (10A) ^ BJB Fuse 101 (30A) ^ BJB Fuse 108 (30A) ^ Central Junction Box (CJB) Fuse 23 (10A) ^ CJB Fuse 13 (10A) ^ Corroded/loose connector(s) ^ Loose/broken wire(s) ^ Failed bulb(s) 3. If the concern is not visually evident, determine the symptom and proceed to the Symptom Chart. See: Towing / Trailer System/Trailer Lamps/Testing and Inspection/Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9831 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9832 Trailer Connector: Pinpoint Tests Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9833 AB1 - AB2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9834 AC1 - AC2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9835 AC3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9836 AD1 - AD2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9837 AD3 Test AE: Trailer Parking Lamps Inoperative Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9838 AE1 - AE2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9839 AE3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9840 AE4 - AE5 Test AF: Trailer Lamp Are Inoperative-Trailer Reversing Lamps Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9841 AF1 - AF2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9842 AF3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9843 AF4 - AF5 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9844 AG1 - AG2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9845 AG3 - AG4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9846 AH1 - AH2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Testing and Inspection > Flow of Diagnosis > Page 9847 AH3 - AH5 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Testing and Inspection > Page 9848 73 Digital Multimeter Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Service and Repair Cowl: Service and Repair REMOVAL 1. Remove the windshield wiper pivot arms. 1 Remove the two covers. 2 Remove the two nuts. 3 Remove the windshield wiper pivot arms. 2. Raise and support the hood. 3. Remove the cowl grille seal. 4. Remove the LH cowl grille. 1 Remove the screw cover. 2 Remove the screws. 3 Remove the clips. 4 Remove the pin-type retainer. 5 Remove the LH cowl grille. NOTE: The two cowl grilles overlap at the center.The LH cowl grille must be removed first. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Service and Repair > Page 9853 5. Remove the RH cowl grille. 1 Remove the screw cover. 2 Remove the screws. 3 Remove the clips. 4 Remove the pin-type retainer. 5 Remove the RH cowl grille. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Adjust the wiper arms. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair Front Door Exterior Handle: Service and Repair REMOVAL 1. Remove the front door trim panel. NOTE: The front door window glass must be completely up. 2. Position the watershield aside. 3. Remove the rear glass run channel bolt and position the glass channel aside. 4. Remove the outside front door handle. 1. Remove the nuts. 2. Disconnect the front door latch to lock cylinder rod. 3. Disconnect the front door latch to outside front door handle rod at the handle and at the latch. 4. Remove the outside front door handle. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair > Page 9861 1. To install, reverse the removal procedure. NOTE: Make sure the door handle release rod is not preloading the latch. It should be clipped in a relaxed state with no slack. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair Front Door Interior Handle: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Remove and position the inside door handle aside. 1. Remove the screw. 2. Remove and position the inside door handle aside. 3. Disconnect the inside door handle cable. INSTALLATION 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Front Door Front Door Latch: Service and Repair Front Door REMOVAL 1. Remove the front door trim panel. 2. Position the watershield aside. 3. Remove the rear glass channel bolt and position the glass channel aside. 4. Disconnect the rods from the door latch. 1. Disconnect the lock cylinder rod. 2. Unclip the locking clip. 3. Disconnect the door lock rod. 5. Position the front door latch aside. 1. Remove and discard the screws. 2. Position the latch aside. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Front Door > Page 9869 6. Disconnect the electrical connectors. 7. Remove the latch. 1. Disconnect the cable from the latch. INSTALLATION 1. To install, reverse the removal procedure. 1. If necessary, use Multi-Purpose Grease Spray F5AZ-19G209-AA or equivalent meeting Ford specification ESR-M1C159-A to lubricate the latches. NOTE: Install the front door latch screw in the small opening first, followed by the large opening. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Front Door > Page 9870 Front Door Latch: Service and Repair Remote Control, Audio - Stereo Heavy Duty Riveter Special Tool(s) REMOVAL 1. Remove the rear door trim panel. 2. Remove the rear door radio speaker. 1. Remove the screws. 2. Disconnect the electrical connector. 3. Remove the rear door radio speaker. 3. Carefully peel off the rear door watershield. 4. Disconnect the necessary rods and cables from the rear door latch remote control. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Front Door > Page 9871 5. Remove the rear door latch remote control. 1. Drill out the rivets. 2. Remove the rear door latch remote control. INSTALLATION 1. To install, reverse the removal procedure. - Using Heavy Duty Riveter, install the rivets. NOTE: Make sure the rear door latch remote control rods are not preloading the latch. They should be clipped in a relaxed state with no slack. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest: > 03-2-4 > Feb > 03 > Body - Driver Side Window Binds When Operated Front Door Panel: Customer Interest Body - Driver Side Window Binds When Operated Article No. 03-2-4 02/03/03 ^ BODY - DRIVER SIDE WINDOW BINDS WHEN OPERATED ^ ELECTRICAL - DRIVER SIDE WINDOW BINDS WHEN OPERATED FORD: 1997-2002 F-150 ISSUE Some vehicles may exhibit a driver's side door glass that binds when operated. This may be caused by the inner door panel developing a crack where the rear window run attaches. When the window is operated, the run flexes and causes the glass to bind in the run. ACTION Install a Reinforcement Plate Kit (XL3Z-15211B06-AA) on the inner door panel. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove door trim panel per the appropriate model year Workshop Manual. 2. Remove the current rear window run attachment bolt and discard. 3. Hold reinforcement plate (included in kit) in position (Figure 1) and mark the area where it will mount. 4. Use sand paper to rough up the area where the outer edge of the plate will mount. 5. Apply TA-12 Structural Foam to the reinforcement plate. 6. Place reinforcement plate in position and install the new bolt and washer assembly (included with kit). Torque the bolt to 8.4-11.5 Lb-ft (11.4-15.6 N.m). 7. Using the five holes around the perimeter of the plate as a guide, drill 3/16 inch (4.76 mm) holes in the inner door panel and install five rivets (included with kit). 8. Apply heat gun at 120° F (49° C) for up to 20 minutes to cure the Structural Foam. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Customer Interest: > 03-2-4 > Feb > 03 > Body - Driver Side Window Binds When Operated > Page 9880 9. Re-install the door trim panel. 10. Verify proper operation. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 030204A Install Reinforcement Plate 1.1 Hrs. On The Inner Door Panel (Includes Time To Remove And Install Watershield): 1997-1998 F-150 030204B Install Reinforcement Plate 0.9 Hr. On The Inner Door Panel (Includes Time To Remove And Install Watershield): 1999-2002 F-150 DEALER CODING CONDITION BASIC PART NO. CODE 1520255 01 OASIS CODES: 102000, 111000 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 03-2-4 > Feb > 03 > Body - Driver Side Window Binds When Operated Front Door Panel: All Technical Service Bulletins Body - Driver Side Window Binds When Operated Article No. 03-2-4 02/03/03 ^ BODY - DRIVER SIDE WINDOW BINDS WHEN OPERATED ^ ELECTRICAL - DRIVER SIDE WINDOW BINDS WHEN OPERATED FORD: 1997-2002 F-150 ISSUE Some vehicles may exhibit a driver's side door glass that binds when operated. This may be caused by the inner door panel developing a crack where the rear window run attaches. When the window is operated, the run flexes and causes the glass to bind in the run. ACTION Install a Reinforcement Plate Kit (XL3Z-15211B06-AA) on the inner door panel. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove door trim panel per the appropriate model year Workshop Manual. 2. Remove the current rear window run attachment bolt and discard. 3. Hold reinforcement plate (included in kit) in position (Figure 1) and mark the area where it will mount. 4. Use sand paper to rough up the area where the outer edge of the plate will mount. 5. Apply TA-12 Structural Foam to the reinforcement plate. 6. Place reinforcement plate in position and install the new bolt and washer assembly (included with kit). Torque the bolt to 8.4-11.5 Lb-ft (11.4-15.6 N.m). 7. Using the five holes around the perimeter of the plate as a guide, drill 3/16 inch (4.76 mm) holes in the inner door panel and install five rivets (included with kit). 8. Apply heat gun at 120° F (49° C) for up to 20 minutes to cure the Structural Foam. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 03-2-4 > Feb > 03 > Body - Driver Side Window Binds When Operated > Page 9886 9. Re-install the door trim panel. 10. Verify proper operation. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 030204A Install Reinforcement Plate 1.1 Hrs. On The Inner Door Panel (Includes Time To Remove And Install Watershield): 1997-1998 F-150 030204B Install Reinforcement Plate 0.9 Hr. On The Inner Door Panel (Includes Time To Remove And Install Watershield): 1999-2002 F-150 DEALER CODING CONDITION BASIC PART NO. CODE 1520255 01 OASIS CODES: 102000, 111000 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 99-8-15 > May > 99 > Interior Door Trim Panel - Replacement Tip Front Door Panel: All Technical Service Bulletins Interior Door Trim Panel - Replacement Tip Article No. 99-8-15 05/03/99 INTERIOR TRIM - DOOR TRIM PANEL REPLACEMENT - SERVICE TIP FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, MUSTANG 1996-1999 ESCORT, TAURUS 1998-1999 ESCORT ZX2 LINCOLN-MERCURY: 1993-1998 MARK VIII 1995-1997 COUGAR 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, TOWN CAR 1996-1999 SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1993-1996 BRONCO 1993-1997 F SUPER DUTY, F-250 HD, F-350 1993-1999 F-150, F-250 LD 1995-1997 AEROSTAR 1995-1999 ECONOLINE, EXPLORER, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE There has been an increase in the number of door trim panel replacements due to damage. This may be caused by a misconception of the type of fastener used to secure the door trim panel. ACTION Review the appropriate model/year Service/Workshop Manual, Section 01-05/501-05 prior to removing the door trim panel. Use the Quick Reference Guide at the end of this article to determine the type of fastener used for the vehicle being worked on. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 99-8-15 > May > 99 > Interior Door Trim Panel - Replacement Tip > Page 9891 For a door trim panel with "molded hook" design, Figure 1 displays the correct direction of force applied during the door trim panel removal procedure. Refer to the Door Trim Panel Attachment Scheme Chart to identify vehicles with molded hook designs. WARNING REMOVE ALL THE SCREWS AND TWO-STAGE PINS BEFORE ATTEMPTING TO REMOVE TRIM PANEL. Detailed instructions and illustration can be found in the appropriate model/year Service/Workshop Manual, Section 01-05/501-05. OTHER APPLICABLE ARTICLES: NONE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Panel: > 99-8-15 > May > 99 > Interior Door Trim Panel - Replacement Tip > Page 9892 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 107000,112000,190000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > 99-8-15 > May > 99 > Interior Door Trim Panel - Replacement Tip Front Door Panel: All Technical Service Bulletins Interior Door Trim Panel - Replacement Tip Article No. 99-8-15 05/03/99 INTERIOR TRIM - DOOR TRIM PANEL REPLACEMENT - SERVICE TIP FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, MUSTANG 1996-1999 ESCORT, TAURUS 1998-1999 ESCORT ZX2 LINCOLN-MERCURY: 1993-1998 MARK VIII 1995-1997 COUGAR 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, TOWN CAR 1996-1999 SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1993-1996 BRONCO 1993-1997 F SUPER DUTY, F-250 HD, F-350 1993-1999 F-150, F-250 LD 1995-1997 AEROSTAR 1995-1999 ECONOLINE, EXPLORER, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE There has been an increase in the number of door trim panel replacements due to damage. This may be caused by a misconception of the type of fastener used to secure the door trim panel. ACTION Review the appropriate model/year Service/Workshop Manual, Section 01-05/501-05 prior to removing the door trim panel. Use the Quick Reference Guide at the end of this article to determine the type of fastener used for the vehicle being worked on. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > 99-8-15 > May > 99 > Interior Door Trim Panel - Replacement Tip > Page 9898 For a door trim panel with "molded hook" design, Figure 1 displays the correct direction of force applied during the door trim panel removal procedure. Refer to the Door Trim Panel Attachment Scheme Chart to identify vehicles with molded hook designs. WARNING REMOVE ALL THE SCREWS AND TWO-STAGE PINS BEFORE ATTEMPTING TO REMOVE TRIM PANEL. Detailed instructions and illustration can be found in the appropriate model/year Service/Workshop Manual, Section 01-05/501-05. OTHER APPLICABLE ARTICLES: NONE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > 99-8-15 > May > 99 > Interior Door Trim Panel - Replacement Tip > Page 9899 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 107000,112000,190000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > Page 9900 Front Door Panel: By Symptom Technical Service Bulletin # 03-2-4 Date: 030203 Body - Driver Side Window Binds When Operated Article No. 03-2-4 02/03/03 ^ BODY - DRIVER SIDE WINDOW BINDS WHEN OPERATED ^ ELECTRICAL - DRIVER SIDE WINDOW BINDS WHEN OPERATED FORD: 1997-2002 F-150 ISSUE Some vehicles may exhibit a driver's side door glass that binds when operated. This may be caused by the inner door panel developing a crack where the rear window run attaches. When the window is operated, the run flexes and causes the glass to bind in the run. ACTION Install a Reinforcement Plate Kit (XL3Z-15211B06-AA) on the inner door panel. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove door trim panel per the appropriate model year Workshop Manual. 2. Remove the current rear window run attachment bolt and discard. 3. Hold reinforcement plate (included in kit) in position (Figure 1) and mark the area where it will mount. 4. Use sand paper to rough up the area where the outer edge of the plate will mount. 5. Apply TA-12 Structural Foam to the reinforcement plate. 6. Place reinforcement plate in position and install the new bolt and washer assembly (included with kit). Torque the bolt to 8.4-11.5 Lb-ft (11.4-15.6 N.m). 7. Using the five holes around the perimeter of the plate as a guide, drill 3/16 inch (4.76 mm) holes in the inner door panel and install five rivets Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > Page 9901 (included with kit). 8. Apply heat gun at 120° F (49° C) for up to 20 minutes to cure the Structural Foam. 9. Re-install the door trim panel. 10. Verify proper operation. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 030204A Install Reinforcement Plate 1.1 Hrs. On The Inner Door Panel (Includes Time To Remove And Install Watershield): 1997-1998 F-150 030204B Install Reinforcement Plate 0.9 Hr. On The Inner Door Panel (Includes Time To Remove And Install Watershield): 1999-2002 F-150 DEALER CODING CONDITION BASIC PART NO. CODE 1520255 01 OASIS CODES: 102000, 111000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > Page 9902 Disclaimer Technical Service Bulletin # 03-2-4 Date: 030203 Body - Driver Side Window Binds When Operated Article No. 03-2-4 02/03/03 ^ BODY - DRIVER SIDE WINDOW BINDS WHEN OPERATED ^ ELECTRICAL - DRIVER SIDE WINDOW BINDS WHEN OPERATED FORD: 1997-2002 F-150 ISSUE Some vehicles may exhibit a driver's side door glass that binds when operated. This may be caused by the inner door panel developing a crack where the rear window run attaches. When the window is operated, the run flexes and causes the glass to bind in the run. ACTION Install a Reinforcement Plate Kit (XL3Z-15211B06-AA) on the inner door panel. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove door trim panel per the appropriate model year Workshop Manual. 2. Remove the current rear window run attachment bolt and discard. 3. Hold reinforcement plate (included in kit) in position (Figure 1) and mark the area where it will mount. 4. Use sand paper to rough up the area where the outer edge of the plate will mount. 5. Apply TA-12 Structural Foam to the reinforcement plate. 6. Place reinforcement plate in position and install the new bolt and washer assembly (included with kit). Torque the bolt to 8.4-11.5 Lb-ft (11.4-15.6 N.m). 7. Using the five holes around the perimeter of the plate as a guide, drill 3/16 inch (4.76 mm) holes in the inner door panel and install five rivets (included with kit). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Door Panel: > Page 9903 8. Apply heat gun at 120° F (49° C) for up to 20 minutes to cure the Structural Foam. 9. Re-install the door trim panel. 10. Verify proper operation. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 030204A Install Reinforcement Plate 1.1 Hrs. On The Inner Door Panel (Includes Time To Remove And Install Watershield): 1997-1998 F-150 030204B Install Reinforcement Plate 0.9 Hr. On The Inner Door Panel (Includes Time To Remove And Install Watershield): 1999-2002 F-150 DEALER CODING CONDITION BASIC PART NO. CODE 1520255 01 OASIS CODES: 102000, 111000 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door Front Door Panel: Service and Repair Front Door Removal NOTE: SuperCab shown, regular cab similar. 1. Remove the A-pillar assist handle. 1. Remove the four covers. 2. Remove the four screws. 3. Remove the A-pillar assist handle. 2. NOTE: Release the top attachments by pulling inboard first and then upward to release the lower hook. Remove the LH and RH windshield side garnish mouldings. 3. Disconnect the front seat safety belt adjustable D-ring. 1. Pull back the cover. 2. Use Safety Belt Bolt Bit to remove the bolts. 3. Disconnect the front seat safety belt adjustable D-rings. NOTE: Regular cab shown, SuperCab similar. 4. Remove the LH and RH upper comer trim panels. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door > Page 9906 4. If equipped, remove the window regulator switch plate. 1. Lift the front of the window regulator switch plate. 2. Disconnect the electrical connectors. 5. If equipped, remove the window regulator handle. 1. Separate the handle cover from the handle. 2. Remove the screw, 3. Remove the window regulator handle. 4. Remove the spacer. 6. CAUTION: Do not pull directly outward on the front door trim panel, as damage may occur. Remove the front door panel. 1. Remove the screws. 2. Lift and remove the front door trim panel. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door > Page 9907 7. If equipped, twist the courtesy lamp bulb socket one quarter turn and remove the socket from the front door trim panel. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door > Page 9908 Front Door Panel: Service and Repair Front Door Trim Panel REMOVAL 1. Disconnect the battery ground cable. 2. Remove the front door trim moulding. 3. Remove the inside door handle finish panel. NOTE: Use the notch to remove the component. 4. If equipped, remove the window regulator switch plate. 1 Lift the front of the window regulator switch plate. 2 Disconnect the electrical connectors. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door > Page 9909 5. If equipped, remove the window regulator handle. 1 Separate the handle cover from the handle. 2 Remove the screw, 3 Remove the window regulator handle. 4 Remove the spacer. 6. Remove the front door panel. 1 Remove the screws. 2 Lift and remove the front door trim panel. CAUTION: Do not pull directly outward on the front door trim panel, as damage may occur. 7. If equipped, twist the courtesy lamp bulb socket one quarter turn and remove the socket from the front door trim panel. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Front Door > Page 9910 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > Customer Interest for Front Door Window Glass: > 03-2-4 > Feb > 03 > Body - Driver Side Window Binds When Operated Front Door Window Glass: Customer Interest Body - Driver Side Window Binds When Operated Article No. 03-2-4 02/03/03 ^ BODY - DRIVER SIDE WINDOW BINDS WHEN OPERATED ^ ELECTRICAL - DRIVER SIDE WINDOW BINDS WHEN OPERATED FORD: 1997-2002 F-150 ISSUE Some vehicles may exhibit a driver's side door glass that binds when operated. This may be caused by the inner door panel developing a crack where the rear window run attaches. When the window is operated, the run flexes and causes the glass to bind in the run. ACTION Install a Reinforcement Plate Kit (XL3Z-15211B06-AA) on the inner door panel. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove door trim panel per the appropriate model year Workshop Manual. 2. Remove the current rear window run attachment bolt and discard. 3. Hold reinforcement plate (included in kit) in position (Figure 1) and mark the area where it will mount. 4. Use sand paper to rough up the area where the outer edge of the plate will mount. 5. Apply TA-12 Structural Foam to the reinforcement plate. 6. Place reinforcement plate in position and install the new bolt and washer assembly (included with kit). Torque the bolt to 8.4-11.5 Lb-ft (11.4-15.6 N.m). 7. Using the five holes around the perimeter of the plate as a guide, drill 3/16 inch (4.76 mm) holes in the inner door panel and install five rivets (included with kit). 8. Apply heat gun at 120° F (49° C) for up to 20 minutes to cure the Structural Foam. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > Customer Interest for Front Door Window Glass: > 03-2-4 > Feb > 03 > Body - Driver Side Window Binds When Operated > Page 9919 9. Re-install the door trim panel. 10. Verify proper operation. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 030204A Install Reinforcement Plate 1.1 Hrs. On The Inner Door Panel (Includes Time To Remove And Install Watershield): 1997-1998 F-150 030204B Install Reinforcement Plate 0.9 Hr. On The Inner Door Panel (Includes Time To Remove And Install Watershield): 1999-2002 F-150 DEALER CODING CONDITION BASIC PART NO. CODE 1520255 01 OASIS CODES: 102000, 111000 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 03-2-4 > Feb > 03 > Body - Driver Side Window Binds When Operated Front Door Window Glass: All Technical Service Bulletins Body - Driver Side Window Binds When Operated Article No. 03-2-4 02/03/03 ^ BODY - DRIVER SIDE WINDOW BINDS WHEN OPERATED ^ ELECTRICAL - DRIVER SIDE WINDOW BINDS WHEN OPERATED FORD: 1997-2002 F-150 ISSUE Some vehicles may exhibit a driver's side door glass that binds when operated. This may be caused by the inner door panel developing a crack where the rear window run attaches. When the window is operated, the run flexes and causes the glass to bind in the run. ACTION Install a Reinforcement Plate Kit (XL3Z-15211B06-AA) on the inner door panel. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove door trim panel per the appropriate model year Workshop Manual. 2. Remove the current rear window run attachment bolt and discard. 3. Hold reinforcement plate (included in kit) in position (Figure 1) and mark the area where it will mount. 4. Use sand paper to rough up the area where the outer edge of the plate will mount. 5. Apply TA-12 Structural Foam to the reinforcement plate. 6. Place reinforcement plate in position and install the new bolt and washer assembly (included with kit). Torque the bolt to 8.4-11.5 Lb-ft (11.4-15.6 N.m). 7. Using the five holes around the perimeter of the plate as a guide, drill 3/16 inch (4.76 mm) holes in the inner door panel and install five rivets (included with kit). 8. Apply heat gun at 120° F (49° C) for up to 20 minutes to cure the Structural Foam. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 03-2-4 > Feb > 03 > Body - Driver Side Window Binds When Operated > Page 9925 9. Re-install the door trim panel. 10. Verify proper operation. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 030204A Install Reinforcement Plate 1.1 Hrs. On The Inner Door Panel (Includes Time To Remove And Install Watershield): 1997-1998 F-150 030204B Install Reinforcement Plate 0.9 Hr. On The Inner Door Panel (Includes Time To Remove And Install Watershield): 1999-2002 F-150 DEALER CODING CONDITION BASIC PART NO. CODE 1520255 01 OASIS CODES: 102000, 111000 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > Page 9926 Front Door Window Glass: By Symptom Technical Service Bulletin # 03-2-4 Date: 030203 Body - Driver Side Window Binds When Operated Article No. 03-2-4 02/03/03 ^ BODY - DRIVER SIDE WINDOW BINDS WHEN OPERATED ^ ELECTRICAL - DRIVER SIDE WINDOW BINDS WHEN OPERATED FORD: 1997-2002 F-150 ISSUE Some vehicles may exhibit a driver's side door glass that binds when operated. This may be caused by the inner door panel developing a crack where the rear window run attaches. When the window is operated, the run flexes and causes the glass to bind in the run. ACTION Install a Reinforcement Plate Kit (XL3Z-15211B06-AA) on the inner door panel. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove door trim panel per the appropriate model year Workshop Manual. 2. Remove the current rear window run attachment bolt and discard. 3. Hold reinforcement plate (included in kit) in position (Figure 1) and mark the area where it will mount. 4. Use sand paper to rough up the area where the outer edge of the plate will mount. 5. Apply TA-12 Structural Foam to the reinforcement plate. 6. Place reinforcement plate in position and install the new bolt and washer assembly (included with kit). Torque the bolt to 8.4-11.5 Lb-ft (11.4-15.6 N.m). 7. Using the five holes around the perimeter of the plate as a guide, drill 3/16 inch (4.76 mm) holes in the inner door panel and install five rivets Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > Page 9927 (included with kit). 8. Apply heat gun at 120° F (49° C) for up to 20 minutes to cure the Structural Foam. 9. Re-install the door trim panel. 10. Verify proper operation. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 030204A Install Reinforcement Plate 1.1 Hrs. On The Inner Door Panel (Includes Time To Remove And Install Watershield): 1997-1998 F-150 030204B Install Reinforcement Plate 0.9 Hr. On The Inner Door Panel (Includes Time To Remove And Install Watershield): 1999-2002 F-150 DEALER CODING CONDITION BASIC PART NO. CODE 1520255 01 OASIS CODES: 102000, 111000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > Page 9928 Disclaimer Technical Service Bulletin # 03-2-4 Date: 030203 Body - Driver Side Window Binds When Operated Article No. 03-2-4 02/03/03 ^ BODY - DRIVER SIDE WINDOW BINDS WHEN OPERATED ^ ELECTRICAL - DRIVER SIDE WINDOW BINDS WHEN OPERATED FORD: 1997-2002 F-150 ISSUE Some vehicles may exhibit a driver's side door glass that binds when operated. This may be caused by the inner door panel developing a crack where the rear window run attaches. When the window is operated, the run flexes and causes the glass to bind in the run. ACTION Install a Reinforcement Plate Kit (XL3Z-15211B06-AA) on the inner door panel. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove door trim panel per the appropriate model year Workshop Manual. 2. Remove the current rear window run attachment bolt and discard. 3. Hold reinforcement plate (included in kit) in position (Figure 1) and mark the area where it will mount. 4. Use sand paper to rough up the area where the outer edge of the plate will mount. 5. Apply TA-12 Structural Foam to the reinforcement plate. 6. Place reinforcement plate in position and install the new bolt and washer assembly (included with kit). Torque the bolt to 8.4-11.5 Lb-ft (11.4-15.6 N.m). 7. Using the five holes around the perimeter of the plate as a guide, drill 3/16 inch (4.76 mm) holes in the inner door panel and install five rivets (included with kit). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > Page 9929 8. Apply heat gun at 120° F (49° C) for up to 20 minutes to cure the Structural Foam. 9. Re-install the door trim panel. 10. Verify proper operation. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 030204A Install Reinforcement Plate 1.1 Hrs. On The Inner Door Panel (Includes Time To Remove And Install Watershield): 1997-1998 F-150 030204B Install Reinforcement Plate 0.9 Hr. On The Inner Door Panel (Includes Time To Remove And Install Watershield): 1999-2002 F-150 DEALER CODING CONDITION BASIC PART NO. CODE 1520255 01 OASIS CODES: 102000, 111000 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > Page 9930 Front Door Window Glass: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Peel back the front door watershield. 3. Lower the window glass to access the two window glass to regulator nuts. 4. Remove the inside glass weatherstrip. 5. Remove the rear glass channel bolt and lift the channel. 6. Loosen the window glass to regulator nuts. - Slide glass channel rearward until the rear glass to regulator nut lines up with the hole in the glass channel. 7. Remove the front door window glass. NOTE: Slide the glass through the outboard side of the door. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > System Information > Technical Service Bulletins > Page 9931 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair Front Door Window Regulator: Service and Repair Heavy Duty Riverter Special Tool(s) REMOVAL 1. Remove the front door trim panel. 2. Peel back the front door watershield. 3. Lower the front door window glass to access the two window regulator nuts. 4. Remove the window glass nuts. 5. Support the front door window glass in the full up position. 6. If equipped, disconnect the power window electrical connector. 7. Remove the window regulator. 1 Remove the nuts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Page 9935 2 Drill out the rivets. 3 Remove the window regulator. INSTALLATION 1. To install, reverse the removal procedure. - Use Heavy Duty Riveter to install the new rivets. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair Rear Door Exterior Handle: Service and Repair Heavy Duty Riveter Special Tool(s) REMOVAL 1. Remove the rear door trim panel. 2. Remove the rear door radio speaker. 1. Remove the screws. 2. Disconnect the electrical connector. 3. Remove the rear door radio speaker. 3. Carefully peel off the rear door watershield. 4. Disconnect the two outside rear door handle rods from the rear door latch remote control. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair > Page 9941 5. Remove the outside rear door handle. 1. Drill out the rivets. 2. Position the outside rear door handle for access. 3. Remove the outside rear door handle. INSTALLATION 1. To install, reverse the removal procedure. 1. Using Heavy Duty Riveter, install the new rivets. NOTE: Make sure the rear door handle rods are not preloading the rear door latch remote control. They should be clipped in a relaxed state with no slack. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Service and Repair Rear Door Interior Handle: Service and Repair REMOVAL 1. Remove the rear door trim panel. 2. Remove the rear door radio speaker. 1. Remove the screws. 2. Disconnect the electrical connector. 3. Remove the rear door radio speaker. 3. Carefully peel off the rear door watershield. 4. Remove the inside rear door handle. 1. Remove the nuts. 2. Remove the inside rear door handle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Service and Repair > Page 9945 5. Remove the rear door inside handle remote control. 1. Rotate the rear door inside handle remote control downward. 2. Disconnect the rear door handle remote control rod. INSTALLATION 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Lower Rear Door Latch: Service and Repair Lower REMOVAL 1. Remove the rear door trim panel. 2. Remove the rear door radio speaker. 1. Remove the screws. 2. Disconnect the electrical connector. 3. Remove the rear door radio speaker. 3. Carefully peel off the rear door watershield. 4. Position the lower rear door latch outside of the door. 1. Remove the screws. 2. Position the lower rear door latch outside of the door. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Lower > Page 9950 5. Remove the lower rear door latch. 1. Disconnect the cable. INSTALLATION 1. To install, reverse the removal procedure. 1. If necessary, use Multi-Purpose Grease Spray F5AZ-19G209-AA or equivalent meeting Ford specification ESR-M1C159-A to lubricate the latches. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Lower > Page 9951 Rear Door Latch: Service and Repair Upper REMOVAL 1. Remove the rear door trim panel. 2. Remove the rear door radio speaker. 1. Remove the screws. 2. Disconnect the electrical connector. 3. Remove the rear door radio speaker. 3. Carefully peel off the rear door watershield. 4. Disconnect the upper rear door latch cable. 1. Lift the clip. 2. Pull to release the cable from its seated position. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Lower > Page 9952 5. Remove the upper rear door latch. 1. Remove the screws. 2. Pull the upper rear door latch and the cable up through the door latch opening. INSTALLATION 1. To install, reverse the removal procedure. - If necessary, use Multi-Purpose Grease Spray F5AZ-19G209-AA or equivalent meeting Ford specification ESR-M1C159-A to lubricate the latches. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Interior Door Trim Panel - Replacement Tip Rear Door Panel: Technical Service Bulletins Interior Door Trim Panel - Replacement Tip Article No. 99-8-15 05/03/99 INTERIOR TRIM - DOOR TRIM PANEL REPLACEMENT - SERVICE TIP FORD: 1995-1997 PROBE, THUNDERBIRD 1995-1999 CONTOUR, CROWN VICTORIA, MUSTANG 1996-1999 ESCORT, TAURUS 1998-1999 ESCORT ZX2 LINCOLN-MERCURY: 1993-1998 MARK VIII 1995-1997 COUGAR 1995-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, TOWN CAR 1996-1999 SABLE, TRACER 1999 COUGAR LIGHT TRUCK: 1993-1996 BRONCO 1993-1997 F SUPER DUTY, F-250 HD, F-350 1993-1999 F-150, F-250 LD 1995-1997 AEROSTAR 1995-1999 ECONOLINE, EXPLORER, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE There has been an increase in the number of door trim panel replacements due to damage. This may be caused by a misconception of the type of fastener used to secure the door trim panel. ACTION Review the appropriate model/year Service/Workshop Manual, Section 01-05/501-05 prior to removing the door trim panel. Use the Quick Reference Guide at the end of this article to determine the type of fastener used for the vehicle being worked on. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Interior Door Trim Panel - Replacement Tip > Page 9957 For a door trim panel with "molded hook" design, Figure 1 displays the correct direction of force applied during the door trim panel removal procedure. Refer to the Door Trim Panel Attachment Scheme Chart to identify vehicles with molded hook designs. WARNING REMOVE ALL THE SCREWS AND TWO-STAGE PINS BEFORE ATTEMPTING TO REMOVE TRIM PANEL. Detailed instructions and illustration can be found in the appropriate model/year Service/Workshop Manual, Section 01-05/501-05. OTHER APPLICABLE ARTICLES: NONE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Technical Service Bulletins > Interior Door Trim Panel - Replacement Tip > Page 9958 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 107000,112000,190000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Trim Panel - Rear Door Rear Door Panel: Service and Repair Trim Panel - Rear Door REMOVAL 1. Remove the rear door window latch screws. 2. Remove the rear door window garnish. 3. Remove the rear door trim panel. 1 Remove the screws. 2 Remove the nut. 3 Remove the pin-type retainer. Lift and remove the rear door trim panel. CAUTION: Do not pull directly outward on the rear door trim panel, as damage may occur. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Trim Panel - Rear Door > Page 9961 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Trim Panel - Rear Door > Page 9962 Rear Door Panel: Service and Repair Rear Door Removal 1. Remove the rear door window latch screws. 2. Remove the rear door window garnish. 3. CAUTION: Do not pull directly outward on the rear door trim panel, as damage may occur. Remove the rear door trim panel. 1. Remove the screws. 2. Remove the nut. 3. Remove the pin-type retainer. Lift and remove the rear door trim panel. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Trim Panel - Rear Door > Page 9963 Installation To install, reverse the removal procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > System Information > Service and Repair Rear Door Window Glass: Service and Repair REMOVAL NOTE: Hinged glass shown, fixed glass similar. 1. If equipped, remove the rear door window latch screws. 2. Remove the rear door window garnish. 3. Remove the rear door window glass. 1 Remove the nuts. 2 Remove the rear door window glass. 4. Cut the excess foam butyl from the window frame. 5. Pry the window frame from the door. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > System Information > Service and Repair > Page 9967 6. Remove the excess foam butyl from the window opening. INSTALLATION 1. Apply 8 mm foam butyl (part of EOAZ-19562-A), or equivalent meeting Ford specification WSB-M2G234-C to the rear window frame. - Start at the bottom middle and work around the frame. NOTE: When applying foam butyl, leave a slight overlap at the bottom to allow for drainage. 2. Install the rear window frame and glass. 1 Position the rear window frame and glass. 2 Tighten the nuts to specification. NOTE: Loosely install all nuts before tightening. 3. Install the rear door window garnish. 4. If equipped, install the rear door window latch screws. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Specifications Rear Door Window Regulator: Specifications Window Glass to Regulator Nuts .................................................................................................................................................... 10-14 Nm (7.4-10 ft lbs) Window Regulator Nuts ................................................................................ .................................................................................. 10-14 Nm (7.4-10 ft lbs) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Specifications Hood Latch: Specifications Hood Latch Bolts ................................................................................................................................. ....................................... 10.2-13.8 Nm (8-10 ft lbs) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Specifications > Page 9975 Hood Latch: Service and Repair REMOVAL 1. Raise and support the hood. 2. Remove the upper air deflector. 1. Remove the screws. 2. Remove the upper air deflector 3. Remove the hood latch. 1. Remove the bolts. 2. Disconnect the hood latch cable from the hood latch. 3. Remove the hood latch. INSTALLATION 1. Install the hood latch. 1. Position the hood latch. 2. Install the hood latch cable. 3. Finger-tighten the bolts. 2. Close the hood. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Specifications > Page 9976 3. Adjust the hood latch and tighten the two hood latch bolts. - If necessary, us Multi-Purpose Grease Spray or equivalent meeting Ford specification ESR-M1C159-A to lubricate the latch. 4. Raise and support the hood. 5. Install the upper air deflector. 1. Position the upper air deflector. 2. Install the screws. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release > Component Information > Specifications Hood Latch Release: Specifications Hood Latch Release Handle Screws ............................................................................................................................................. 2.7-3.7 Nm (24-33 in lbs) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release > Component Information > Specifications > Page 9980 Hood Latch Release: Service and Repair HOOD LATCH RELEASE HANDLE REMOVAL 1. Remove the instrument panel steering column cover. 2. Remove the hood latch release handle. 1. Remove the screws. 2. Disconnect the hood latch cable. 3. Remove the hood latch release handle. INSTALLATION 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Revised Article No. 01-21-6 10/29/01 ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE MERCURY HOOD LAMP SWITCH FORD: 1987-1995 TAURUS 1988-1991 CROWN VICTORIA 1989 THUNDERBIRD 1989-1996 MUSTANG 1994-1996 THUNDERBIRD 1990 BRONCO II 1990-1996 RANGER 1991-1996 BRONCO 1994-2001 EXPLORER 1997-2001 F-150 2000-2001 EXCURSION 2002 EXPEDITION LINCOLN: 1989-1994 CONTINENTAL 1990-1992 MARK VII 1990-1996 TOWN CAR 1993-1995 MARK VIII 2002 NAVIGATOR MERCURY: 1987-1995 SABLE 1988-1991 GRAND MARQUIS 1989 COUGAR 1994-1996 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is to provide information on replacement hood lamp switches. The 27 degree Mercury style hood switches will no longer be available. Replacement 27 degree Mechanical switches will be available as a service replacement. ACTION For vehicles requiring hood lamp switch replacement, replace the 27 degree Mercury switch with new 27 degree Mechanical switch. Replace hood lamp switch per the appropriate model year Workshop Manual as needed. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised > Page 9986 OASIS CODES: 201000, 201200 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Trunk / Liftgate Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9992 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9993 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9994 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9995 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 9996 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Recalls for Frame: > 98S34 > Dec > 98 > Recall - Tow Hook Replacement Technical Service Bulletin # 98S34 Date: 981201 Recall - Tow Hook Replacement SAFETY RECALL 98S34 Certain 1999 model year regular and Super-Duty F-250/350 series trucks built at the Kentucky Truck Plant on September 25, 1998 ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Requirements ^ Attachment III ^ Technical Information ^ Customer Notification Letter Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Recalls for Frame: > 98S34 > Dec > 98 > Recall - Tow Hook Replacement > Page 10005 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT -- Affected vehicles on the enclosed list. -- Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTRACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter and schedule a service date. REGIONAL CONTACT Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Recalls for Frame: > 98S34 > Dec > 98 > Recall - Tow Hook Replacement > Page 10006 Advise regional office if: -- an owner cannot be contacted. -- an owner does not make a service date. CLAIMS SUBMISSION Enter claims using DWE. See ACESII Manual, Sections 5 & 6. WARRANTY AND POLICY MANUAL See Sections 5 and 6 of the ACESII Manual. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels. NOTE: DESTROY REMOVED CAST TOW HOOKS DEALER PRICE For latest prices, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information AFFECTED VEHICLES: 1999 Model Year Regular and Super Duty F-250/350 Series Trucks SERVICE PROCEDURE 1. Remove front bumper lower splash shield push pins. 2. Disconnect block heater power cord retainers from bumper if equipped. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Recalls for Frame: > 98S34 > Dec > 98 > Recall - Tow Hook Replacement > Page 10007 3. Measure and record distance between top of front bumper and turn signal lamp housings. This measurement is to ensure bumper is reinstalled in same location. See Figure 1. 4. Position jacks to support front bumper. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Recalls for Frame: > 98S34 > Dec > 98 > Recall - Tow Hook Replacement > Page 10008 5. Remove bumper retaining bolts and with the help of an assistant, remove bumper from vehicle. See Figure 2. 6. Using 3/8-inch drive l5mm socket and an extension, remove tow hook retaining bolts and remove both tow hooks. See Figure 3. CAUTION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Recalls for Frame: > 98S34 > Dec > 98 > Recall - Tow Hook Replacement > Page 10009 Be sure to destroy and discard removed tow hooks. 7. Install new tow hooks and tighten bolts to 103 Nm (76 lb-ft). 8. With the help of an assistant, position bumper and install retaining bolts snug. 9. Adjust bumper height using dimensions recorded during Step 3. Center bumper side-to-side. 10. Tighten bumper retaining bolts to 80 Nm (59 lb-ft). 11. Remove supporting jacks. 12. Connect block heater power cord retainers to bumper if equipped. 13. Position splash shield and install push pins. 14. Clean front bumper. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Recalls for Frame: > 98S34 > Dec > 98 > Recall - Tow Hook Replacement > Page 10010 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > Recalls for Frame: > 98S34 > Dec > 98 > Recall - Tow Hook Replacement > Page 10011 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Frame: > 98S34 > Dec > 98 > Recall - Tow Hook Replacement Technical Service Bulletin # 98S34 Date: 981201 Recall - Tow Hook Replacement SAFETY RECALL 98S34 Certain 1999 model year regular and Super-Duty F-250/350 series trucks built at the Kentucky Truck Plant on September 25, 1998 ^ Dealer Letter ^ Attachment I ^ Administrative Information ^ Attachment II ^ Labor Allowances ^ Parts Requirements ^ Attachment III ^ Technical Information ^ Customer Notification Letter Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Frame: > 98S34 > Dec > 98 > Recall - Tow Hook Replacement > Page 10017 Attachment I - Administrative Information OASIS You must use OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE Correct all vehicles in stock before delivery. Federal law requires dealers to complete any outstanding safety recall service before a new vehicle is delivered to the buyer or lessee. Violation of this requirement by a dealer could result in a civil penalty of up to $1,100 per vehicle. PROMPTLY CORRECT -- Affected vehicles on the enclosed list. -- Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTRACT Immediately contact any affected owner whose name is not on the list. Give owner a copy of the Owner Letter and schedule a service date. REGIONAL CONTACT Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Frame: > 98S34 > Dec > 98 > Recall - Tow Hook Replacement > Page 10018 Advise regional office if: -- an owner cannot be contacted. -- an owner does not make a service date. CLAIMS SUBMISSION Enter claims using DWE. See ACESII Manual, Sections 5 & 6. WARRANTY AND POLICY MANUAL See Sections 5 and 6 of the ACESII Manual. Attachment II - Labor and Parts Information LABOR ALLOWANCES PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels. NOTE: DESTROY REMOVED CAST TOW HOOKS DEALER PRICE For latest prices, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book EXCESS STOCK RETURN Excess stock returned for credit must have been purchased from Ford Customer Service Division in accordance with Policy Procedure Bulletin 4000. Attachment III - Technical Information AFFECTED VEHICLES: 1999 Model Year Regular and Super Duty F-250/350 Series Trucks SERVICE PROCEDURE 1. Remove front bumper lower splash shield push pins. 2. Disconnect block heater power cord retainers from bumper if equipped. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Frame: > 98S34 > Dec > 98 > Recall - Tow Hook Replacement > Page 10019 3. Measure and record distance between top of front bumper and turn signal lamp housings. This measurement is to ensure bumper is reinstalled in same location. See Figure 1. 4. Position jacks to support front bumper. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Frame: > 98S34 > Dec > 98 > Recall - Tow Hook Replacement > Page 10020 5. Remove bumper retaining bolts and with the help of an assistant, remove bumper from vehicle. See Figure 2. 6. Using 3/8-inch drive l5mm socket and an extension, remove tow hook retaining bolts and remove both tow hooks. See Figure 3. CAUTION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Frame: > 98S34 > Dec > 98 > Recall - Tow Hook Replacement > Page 10021 Be sure to destroy and discard removed tow hooks. 7. Install new tow hooks and tighten bolts to 103 Nm (76 lb-ft). 8. With the help of an assistant, position bumper and install retaining bolts snug. 9. Adjust bumper height using dimensions recorded during Step 3. Center bumper side-to-side. 10. Tighten bumper retaining bolts to 80 Nm (59 lb-ft). 11. Remove supporting jacks. 12. Connect block heater power cord retainers to bumper if equipped. 13. Position splash shield and install push pins. 14. Clean front bumper. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Frame: > 98S34 > Dec > 98 > Recall - Tow Hook Replacement > Page 10022 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Frame: > 98S34 > Dec > 98 > Recall - Tow Hook Replacement > Page 10023 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Customer Interest for Console: > 99-8-12 > May > 99 > Console - Storage Bin Detaches Console: Customer Interest Console - Storage Bin Detaches Article No. 99-8-12 05/03/99 INTERIOR - STORAGE BIN INSIDE CONSOLE DETACHES FROM BOX - SUPER CAB VEHICLES BUILT THROUGH 4/1/1999 LIGHT TRUCK: 1999 F-150, F-250 LD ISSUE The storage bin inside the console may fall dawn inside the console base on some vehicles. This may be caused by the box warping and not fitting properly on the lip of the base. ACTION Drill a hole and add two (2) rubber bumpers for spacers. The spacers will increase the surface contact area and reduce the possibility of the bin falling. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Drill two (2) 3 mm (1/8") diameter holes through the upper left side wall approximately 25 mm (1") from each end (figure 1). 2. insert two (2) small, conical head Bumpers - (N805844-S) into the drilled holes from the outside. 3. Cut off the bumper tails on the inside of the bin. PART NUMBER PART NAME N8O5844-S Bumper OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Customer Interest for Console: > 99-8-12 > May > 99 > Console - Storage Bin Detaches > Page 10033 990812A Install Bumpers 0.3 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 19A090 33 OASIS CODES: 107000, 207000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 99-8-12 > May > 99 > Console - Storage Bin Detaches Console: All Technical Service Bulletins Console - Storage Bin Detaches Article No. 99-8-12 05/03/99 INTERIOR - STORAGE BIN INSIDE CONSOLE DETACHES FROM BOX - SUPER CAB VEHICLES BUILT THROUGH 4/1/1999 LIGHT TRUCK: 1999 F-150, F-250 LD ISSUE The storage bin inside the console may fall dawn inside the console base on some vehicles. This may be caused by the box warping and not fitting properly on the lip of the base. ACTION Drill a hole and add two (2) rubber bumpers for spacers. The spacers will increase the surface contact area and reduce the possibility of the bin falling. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Drill two (2) 3 mm (1/8") diameter holes through the upper left side wall approximately 25 mm (1") from each end (figure 1). 2. insert two (2) small, conical head Bumpers - (N805844-S) into the drilled holes from the outside. 3. Cut off the bumper tails on the inside of the bin. PART NUMBER PART NAME N8O5844-S Bumper OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 99-8-12 > May > 99 > Console - Storage Bin Detaches > Page 10039 990812A Install Bumpers 0.3 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 19A090 33 OASIS CODES: 107000, 207000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Page 10040 Console: Service and Repair REMOVAL 1. Open the floor console cover. 2. If equipped, remove the CD changer. 3. Remove the floor console tray mat. 4. Remove the floor console cupholder assembly. 5. Remove the floor console. 1. Remove the nuts. 2. Remove the floor console. 1. Feed the wiring harness through the floor console. INSTALLATION 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. - To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming Deactivation Procedure 1. Disconnect the battery ground cable. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the driver air bag module from the vehicle. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set an air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. 4. Connect an air bag simulator to the vehicle harness at the top of the steering column. 5. Disconnect the passenger air bag module electrical connector. 6. Connect an air bag simulator to the vehicle harness. 7. Reconnect the battery ground cable. Reactivation Procedure 1. Disconnect the battery ground cable. WARNING: The air bag simulators must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the air bag simulator from the vehicle harness connector at the top of the steering column. 4. Install the driver air bag module. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. 5. Remove the air bag simulator from the vehicle harness connector at the passenger air bag module. 6. Connect the passenger air bag module electrical connector. 7. Reconnect the battery ground cable. 8. Prove out the system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 10047 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist should be completed following diagnosis or repair of any air bag system concern. 1. Is the connector at the base of the steering column connected? ................................................................................................................................ [ ] 2. Are the air bag modules connected? ............................................................................................... .......................................................................... [ ] 3. Is the Restraints Control Module (RCM) connected? ............................................................................................................................................... [ ] 4. Is the vehicle battery connected? .................................................................................................... .......................................................................... [ ] Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair Glove Compartment: Service and Repair Glove Box Spring Tool Special Tool(s) REMOVAL 1. Open the glove compartment. 2. Lower the glove compartment. 1. Move the glove compartment stop to align with the opening. 2. Lower the glove compartment. 3. Install Glove Box Spring Tool Set. 1. Hold the glove compartment open. 2. Install Glove Box Spring Tool Set. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Component Information > Service and Repair > Page 10051 4. Remove the glove compartment. 1. Remove the bolts. 2. Remove the glove compartment. INSTALLATION 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair Headliner: Service and Repair Safety Belt Bolt Bit SPECIAL TOOL(S) REMOVAL NOTE: SuperCab shown, regular cab similar. 1. Remove the A-pillar assist handle. 1 Remove the four covers. 2 Remove the four screws. 3 Remove the A-pillar assist handle. 2. Remove the LH and RH windshield side garnish mouldings. NOTE: Release the top attachments by pulling inboard first and then upward to release the lower hook. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 10055 3. Disconnect the front seat safety belt adjustable D-ring. 1 Pull back the cover. 2 Use Safety Belt Bolt Bit to remove the bolts. 3 Disconnect the front seat safety belt adjustable D-rings. NOTE: Regular cab shown, SuperCab similar. 4. Remove the LH and RH upper corner trim panels. 5. Remove the coat hooks. 1 Remove the two screws. 2 Remove the two coat hooks. 6. Remove the dome lamp. 1 Carefully remove the lens from the dome lamp. 2 Remove the screws. 3 Remove the dome lamp. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 10056 7. Remove the inside sun visor 1 Remove the screws. 2 Remove the inside sun visor. 8. Remove the center sun visor clip. 1 Remove the screws. 2 Remove the center sun visor clip. 9. Remove the headliner. INSTALLATION NOTE: SuperCab shown, regular cab similar. 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair Trim Panel: Service and Repair Safety Belt Bolt Bit SPECIAL TOOL(S) REMOVAL NOTE: SuperCab shown, regular cab similar. 1. Remove the rear seat back. 2. Using Safety Belt Bolt Bit, remove the rear seat safety belt D-ring bolt. 3. Remove the upper corner trim panel. 1 Remove the pin-type retainer. 2 Release the clips and slide the upper corner trim panel out of the retainers and remove. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Page 10060 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Door Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 10067 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 10068 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 10069 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 10070 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 10071 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Technical Service Bulletins > Page 10072 Door Lock Cylinder: Service and Repair REMOVAL NOTE: Individual lock cylinders are repaired by discarding the inoperative cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle. 1. Remove the front door outside handle. 2. Remove the front door lock cylinder. 1 Remove the spring clip. 2 Remove the front door lock cylinder. INSTALLATION 1. To install, reverse the removal procedure NOTE: Make sure the lock release rod is not preloading the latch. It should be clipped in a relaxed state with no slack. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics Keyless Entry Key-Pad: Technical Service Bulletins Keyless Entry - Keypad Diagnostics TSB 06-15-8 08/07/06 KEYPAD DIAGNOSTICS - DEALER INSTALLED ACCESSORY FORD: 1998-2006 Taurus 1999-2003 Escort 1999-2006 Mustang 2000-2006 Focus 2002-2005 Thunderbird 2005-2006 Five Hundred, Freestyle 2006 Crown Victoria, Fusion 1998-2006 Expedition, Explorer, F-150, Ranger 1999 F-250 Light Duty 1999-2003 Windstar 1999-2006 F-Super Duty 2000-2005 Excursion 2000-2006 E-Series 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004 F-150 Heritage 2004-2006 Freestar LINCOLN: 1998-2006 Town Car 2000-2006 Lincoln LS 2006 Zephyr 1998-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006 Mark LT MERCURY: 1998-2005 Sable 1999-2002 Cougar 2005-2006 Montego 2006 Grand Marquis, Milan 1998-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner ISSUE Some vehicles may experience a concern with the keyless entry keypad. In order to properly diagnose the concern with the keyless entry keypad, it is important to identify whether the keypad is a factory installed style (wired) or a Genuine Ford Accessory (GFA) radio frequency (RF) style keypad. ACTION Use the following Service Procedure to identify GFA RF keypads and provide diagnostic service tips. SERVICE PROCEDURE IDENTIFICATION: 1. Production installed keyless entry keypads are mounted flush with the surface of the vehicle and are wired directly to the module controlling the vehicle's keyless entry system. This style keypad can be diagnosed using the appropriate Workshop Manual (WSM), Section 501-14. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 10078 2. Dealer installed GFA RF keypads are adhesive backed and protrude approximately 1/2" (13 mm) from the surface of the vehicle and there are no specific diagnostics available in the WSM (Figure 1). NOTE THIS RF KEYPAD WAS ALSO US[D IN PRODUCTION ON 2004 F-SUPER DUTY VEHICLES BUILT PRIOR TO 12/3/2003. REFER TO WSM, SECTION 501-14 FOR RF KEYPAD DIAGNOSTICS FOR THESE VEHICLES. GENUINE FORD ACCESSORY KEYPAD DIAGNOSTIC TIPS 1. The keypad operates similarly to a remote keyless entry (RKE) transmitter and is programmed using a similar procedure. Although the RF keypad is not specifically addressed in the WSM, the RKE transmitter programming portion of the WSM, Section 501-14 can be used as a guide NOTE THE 7-8 AND 9-0 BUTTONS ON THE KEYPAD MUST BE PRESSED SIMULTANEOUSLY DURING THE PROCEDURE IN ORDER FOR THE KEYPAD TO BE RECOGNIZED AS AN ADDITIONAL REMOTE TRANSMITTER. Since the GFA RF keypad is essentially another RKE transmitter, the transmitter diagnostic pinpoint tests in the vehicle's WSM can also be referenced even though the buttons serving the lock / unlock functions will differ 2. The GFA RF keypad is serviced as an assembly. The internal battery cannot be replaced separately. 3. If the master code or owner selectable code is lost or forgotten, the GFA RF keypad must be replaced. These codes are not stored in any vehicle module (with the exception of 2004 F-Super Duty vehicles produced prior to 12/3/2003). 4. The GFA RF keypad and all RKE transmitters (the number of transmitters allowable will vary by vehicle) must be reprogrammed together anytime the keypad is replaced, an RKE transmitter is replaced, or the module controlling the keyless entry system on the vehicle (GEM/SJB/VSM/DDM etc.) is replaced. NOTE THERE IS AN EXCEPTION TO TIP 4 FOR VEHICLES EQUIPPED WITH INTEGRATED KEYHEAD TRANSMITTERS (IKTs) (FUSION/MILAN/ZEPHYR). THE GFA RF KEYPADS FOR VEHICLES WITH IKTs MUST BE PROGRAMMED INDEPENDENTLY FROM THE IKTs. TURN THE IGNITION FROM "OFF" TO "RUN" 8 TIMES WITHIN 10 SECONDS, WITH THE 8TH TIME ENDING IN "RUN". THE DOOR LOCKS WILL CYCLE TO CONFIRM ENTERING PROGRAMMING MODE. PRESS THE 7-8 AND 9-0 BUTTON ON THE KEYPAD SIMULTANEOUSLY TO SEND A LOCK SIGNAL. TURN IGNITION TO OFF. THE LOCKS WILL CYCLE AGAIN TO INDICATE THE END OF THE PROGRAMMING MODE. 5. The keypad will normally illuminate for 5 seconds after one or more buttons are pressed, and the illumination will immediately turn off if the 7-8 and 9-0 buttons are pressed simultaneously (lock all doors). The keypad contains an optical sensor and will not illuminate under bright lighting conditions. The keypad may only illuminate briefly in colder temperatures in order to maximize the battery power available to transmit a lock/unlock signal. The temperature at which this occurs will vary depending upon the keypad battery age and condition. Both of these conditions are a normal function of the Power Save Mode and do not indicate a need to replace the keypad. 6. After entering the keypad code, the system may unlock the driver's door, lock it, then unlock it again, and the keypad will not even briefly illuminate. This is the Alert Mode and is an indication that battery power is very low and the keypad must be replaced. 7. The keypad also contains an Anti-scan feature. If the wrong code has been entered 7 times (35 consecutive button presses) the keypad is disabled for one minute and the keypad lamp will flash during this time. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 10079 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 14A626 42 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams Keyless Entry Module: Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Diagrams > Page 10083 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Component Information > Service and Repair Keyless Entry Transmitter: Service and Repair Programming NOTE: ^ All keyless entry remote transmitters must be programmed at the same time. ^ To program (or reprogram) the keyless entry remote transmitter into the RAP module, perform the following steps: 1. Turn the ignition switch from OFF to RUN 8 times within 10 seconds, ending in RUN. If the RAP module has successfully entered program mode, it will lock and then unlock all doors. 2. Within 20 seconds, press any button on a keyless entry remote transmitter, and the doors will lock and then unlock to confirm that each keyless entry remote transmitter has been programmed. Repeat this step for each transmitter. 3. If the door locks do not respond for any keyless entry remote transmitter, wait several seconds and press the button again. If the door locks still fail to respond, refer to Inspection and Verification. See: Testing and Inspection/Initial Inspection and Diagnostic Overview 4. Turn the ignition switch to the OFF position, or wait up 20 seconds after step 2, to exit program mode. If a keyless entry remote transmitter has been programmed (or reprogrammed), the RAP module will lock and unlock all doors one last time to confirm. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Left Power Door Lock Switch Power Door Lock Switch: Diagrams Left Power Door Lock Switch Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Left Power Door Lock Switch > Page 10092 Power Door Lock Switch: Diagrams Right Front Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > With Remote Anti-Theft Personality Power Door Lock Switch: Testing and Inspection With Remote Anti-Theft Personality Left Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > With Remote Anti-Theft Personality > Page 10095 Schematic Right Component Testing Procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > With Remote Anti-Theft Personality > Page 10096 Terminals Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > With Remote Anti-Theft Personality > Page 10097 Power Door Lock Switch: Testing and Inspection Without Remote Anti-Theft Personality Left Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > With Remote Anti-Theft Personality > Page 10098 Schematic Right Component Testing Procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Testing and Inspection > With Remote Anti-Theft Personality > Page 10099 Terminals Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available Trunk / Liftgate Lock Cylinder: Technical Service Bulletins Locks - Lock Service Packages Available Article No. 99-24-2 11/29/99 LOCKS - REPLACE AND/OR REPAIR ANY LOCK COMPONENT - AVAILABILITY OF INDIVIDUAL LOCKS FORD: 1996-2000 CROWN VICTORIA, MUSTANG, TAURUS 1997 THUNDERBIRD 1996 BRONCO, F-150-350 SERIES 1996-1997 AEROSTAR 1996-2000 ECONOLINE, EXPLORER, RANGER 1997 F-250 HD, F-350 1997-2000 EXPEDITION, F-150, F-250 LD 1998-2000 WINDSTAR 1999-2000 SUPER DUTY F SERIES 1996-2000 F & B SERIES LINCOLN: 1996-2000 TOWN CAR 1997-1998 MARK VIII 1997-2000 CONTINENTAL 1998-2000 NAVIGATOR MERCURY: 1996-2000 GRAND MARQUIS, SABLE 1997 COUGAR 1997-2000 MOUNTAINEER Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 10104 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 10105 This TSB article is being republished in its entirety to include vehicles, update model years, and include a Lock Lever Kit Application Chart. ISSUE The current door, decklid, ignition, and stowage locks cannot be serviced individually. Current lock repair practice is to replace the entire lock set (-22050-) when one (1) or more locks must be replaced. The release of this TSB and associated parts will allow replacement of any individual malfunctioning lock (i.e., door lock, ignition lock, decklid lock, etc.) instead of replacing the entire lockset. This TSB only applies to the 8-bit locks introduced in 1996. The 10-bit lock is not affected. ACTION Lock service packages have been released that contain all the necessary components to re-pin a new lock cylinder to the customer's current key code. It allows the service community to replace the individual lock cylinder on a given vehicle rather than replace the entire lockset. For removal and installation procedures for all lock cylinders, refer to the following Service Procedure for details. NOTE MOST MODELS BUILT DURING THE 1996 MODEL YEAR HAVE BOTH THE 10-BIT AND 8-BIT LOCKS ON THEM. CHECK THE BUILD DATE OF THE VEHICLE TO ENSURE THE USE OF THE CORRECT STYLE OF LOCK WHEN SERVICING ANY LOCK ON A 1996 VEHICLE. THE 10-BIT LOCKS ARE NOT AFFECTED BY THIS TSB AND MUST BE SERVICED BY REPLACING THE COMPLETE LOCK SET. THE TWO STYLES ARE NOT INTERCHANGEABLE. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 10106 ^ For ignition lock concerns, see appropriate model/year Service Manual, Section 11-04 or Workshop Manual, Section 211-04. ^ Other lock concerns, see appropriate model/year Service Manual, Section 01-14A or Workshop Manual, Section 501-14. Obtain the lock service package for the vehicle being serviced by referring to the Part Number And Usage Chart for correct application. Determine the matching key cut depth at each key station (any of the following three methods may be used to determine the key cut depth at each key station). ^ Use the OEM key code provided with the vehicle and look up the cut pattern in the key code table (the selling dealer should have the key code or the customer may be able to provide it). A key code table comes with the Rotunda Key Cutter (011-00215). ^ Use a "key decoder" to determine each cut height. A decoder may be included with the Rotunda Key Cutter or can be ordered separately through Rotunda (Decoder Part Number 011-RMT61). Equivalent decoders are commonly available through the locksmith industry. A key decoder is a plate with an elongated slot corresponding to the different key cut heights. ^ Using the customers key, measure the key cut depth at each key station using Figure 2 of the instruction sheet contained within each lock service package. One of the steps in building a new lock is to insert the key and verify the tumblers are flush to the cylinder. This step is clearly spelled out in the instruction sheet. This will ensure that the lock is rebuilt properly before it's installed in the vehicle. Each lock service package will include a unique detailed instruction sheet on how to re-pin that individual lock cylinder. If further assistance is needed, call Ford Motor Company toll-free at (800) 826-4694 (direct dial at (313) 248-4200) between 8:00 AM and 4:30 PM ET (all U.S. and Canadian dealers only). For technical questions regarding the lock service pack re-pinning process, call Ford Interior Systems at (313) 337-3041. A special service tool is required to properly install (crimp) the round dust covers on the door lock cylinder. This special service tool has been provided through a special mailing to all North American servicing dealers. If additional tools are required, contact Rotunda Tools at (800) 768-8632 (direct dial at (810) 574-2332, ask for OTC order desk) to purchase a new tool (501-O51A). NOTE THE SPECIAL SERVICE TOOL (501-051A) IS NOW COMPATIBLE WITH TAURUS/SABLE DOOR LOCK CYLINDER ROUND DUST COVERS. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 10107 A Lock Lever Kit (XF1Z-5421970-AA) containing all the different levels of lock levers needed to service any vehicle is also required to complete this repair. This kit contains levers to service numerous vehicles. For pricing individual levers after each use, enter kit part number or the claim form. This will automatically generate a unit lever price. For an application chart that lists the usage of all levers included in the kit, refer to Figure 1. NOTE THE EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253AD1) HAS BEEN SUPERSEDED BY LEVER KIT (XF1Z-5421970-AA)(STRATTEC 703253AE1). THE EXISTING LEVER KIT IS STILL GOOD AND CAN BE UPDATED WITH THE NEW PARTS. TO ORDER THE UPDATE KITS, CONTACT STRATTEC CORPORATION AT (414) 247-3333 AND ORDER THE UPDATE KIT (UPDATE KIT 599527AA1 WHICH INCLUDES 5 LEVERS (STRATTEC 599467) AND A LABEL FOR THE BOX) AND THE UPDATE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Locks - Lock Service Packages Available > Page 10108 E-CLIP KIT (UPDATE KIT 599528AA1 WHICH INCLUDES 100 E-CLIPS (STRATTEC 94566) AND A LABEL FOR THE BOX) AND ADD THEM TO THEIR EXISTING LEVER KIT (F8DZ-5421970-AA) (STRATTEC 703253) OR ORDER THE NEW LEVER KIT (XF1Z-5421970-AA) (STRATTEC 703253AE) WHICH INCLUDES THE NEW PARTS AND LABELS. THE SEPARATE UPDATE KITS ARE APPROXIMATELY $30.00 PER KIT. NOTE SCRAP LOCK PINNING KITS AND SERVICE PARTS WITH A 1996 AND PRIOR NUMBER. THESE KITS AND PARTS ARE OBSOLETE. A NEW LOCK LEVER KIT (XF1Z-5421970-AA) IS NOW AVAILABLE CONTAINING ALL THE DIFFERENT LEVELS OF LOCK LEVERS NEEDED TO SERVICE ANY VEHICLE. THIS KIT IS REQUIRED TO COMPLETE THIS REPAIR. 1998 Windstar front door locks are not serviceable with the lock service packages. If Windstar front door locks need servicing, the entire lockset will have to be replaced. All other Windstar locks (sliding door, liftgate and ignition) can be serviced using the lock service packages. NOTE 1999 WINDSTAR LOCKS ARE ALL SERVICEABLE WITH LOCK SERVICE PACKAGES. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-23-24 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 112000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams > Left Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams > Left > Page 10114 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams > Left > Page 10115 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Testing and Inspection > Component Testing Procedure Power Mirror Switch: Testing and Inspection Component Testing Procedure Component Testing Procedure (part 1 Of 2) Component Testing Procedure (part 2 Of 2) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Testing and Inspection > Component Testing Procedure > Page 10118 Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Testing and Inspection > Component Testing Procedure > Page 10119 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Testing and Inspection > Component Testing Procedure > Page 10120 Power Mirror Switch: Testing and Inspection Component Tests OUTSIDE REAR VIEW MIRROR CONTROL SWITCH Measure the resistance between the following terminals while pressing the switch in the requested directions: If the resistance is less than 5 ohms in each direction, return to the originating pinpoint test otherwise, replace the switch. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture Technical Service Bulletin # 99-12-10 Date: 990614 Paint - Rough Texture Article No. 99-12-10 06/14/99 ^ PAINT - IRON PARTICLE REMOVAL - INDUSTRIAL FALLOUT - ACID RAIN NEUTRALIZATION ^ PAINT - ROUGH TEXTURE/FERROUS METAL CONTAMINATION - ACID RAIN DISCOLORATION OR ETCHING FORD: 1996-1997 ASPIRE, PROBE, THUNDERBIRD 1996-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1996-1997 COUGAR 1996-1998 MARK VIII 1996-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR LIGHT TRUCK: 1996 BRONCO 1996-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1996-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES MEDIUM/HEAVY TRUCK: 1996-1997 CARGO SERIES 1996-1998 AEROMAX, F SERIES, LOUISVILLE This TSB article is being republished in its entirety to add vehicles and model years, and to revise the procedure to use Ford brand service parts. ISSUE Ford Motor Company has released a private labeled material to be used for iron particle/acid rain service repairs. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 10130 ACTION To remove these particles/contaminates, use ONLY the following products and procedure. No polishing, compounding, color sanding, or repainting should be done before this procedure is performed. This procedure uses products that are acidic, alkaline, and neutral and must be properly mixed and used in their specific order. Refer to the following Service Procedure for details. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 10131 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-21-3 WARRANTY STATUS: Eligible Under The Provisions Of 12 Month/12,000 Mile Basic Warranty Coverage OPERATION DESCRIPTION TIME 991210A Decontaminate And 0.6 Hr. Surface Correction (Aspire, F-450/550, And Cargo) 991210B Decontaminate And 0.7 Hr. Surface Correction (Escort ZX2, Ranger Regular Cab, Probe, Bronco, And Aerostar) 991210C Decontaminate And 0.8 Hr. Surface Correct (Escort/Tracer, Escort/Tracer Wagon, Contour/Mystique, Mustang Convertible/Convertible OT, Taurus/Sable Sedan Or Wagon, 1996-1998 Villager, And 1999 Cougar) 991210D Decontaminate And 0.8 Hr. Surface Correction (F-Series And 1996-97 Thunderbird/Cougar) 991210E Decontaminate And 0.8 Hr. Surface Correction (Ranger SuperCab/Splash, F-150/250 6Ft Bed - Regular Cab/Flare Side Regular Cab, F-250/350 SD 6Ft Bed - Regular Cab, F-450/550 Crew Cab, And Louisville/AeroMax) 991210F Decontaminate And 0.9 Hr. Surface Correction (Mustang Coupe/Coupe GT, Continental, Mark VIII, Ranger Splash SuperCab, Explorer 2-Door, And 1999 Villager) 991210G Decontaminate And 0.9 Hr. Surface Correction (F-150/250 6Ft Bed - SuperCab/8Ft Bed - Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 10132 Regular Cab/Flare Side - SuperCab, And F-250/350 SD 6Ff Bed - SuperCab/8Ft Bed - Regular Cab) 991210H Decontaminate And 1.0 Hr. Surface Correction (Crown Victoria/Grand Marquis, Town Car, Windstar, Explorer 4-Door, And Mountaineer) 9912101 Decontaminate And 1.0 Hr. Surface Correction (F-150/250 8Ft Bed - SuperCab, F-250/350 SD 6Ft Bed - Crew Cab/8Ft Bed SuperCab/8Ft Bed - Crew Cab, And Expedition/Navigator) 991210J Decontaminate And 1.2 Hrs. Surface Correction (Econoline Wagon/Wagon Super-V) 991210k Decontaminate And 1.3 Hrs. Surface Correction (Econoline Cargo) 991210L Decontaminate And 1.4 Hrs. Surface Correction (Econoline Cargo Super-V) DEALER CODING CONDITION BASIC PART NO. CODE ENTRE C8 OASIS CODES: 106000,190000 Service Procedure NOTE ANY CHANGES TO THIS PROCEDURE WILL CAUSE AN INCOMPLETE OR UNSATISFACTORY REPAIR. THE USE OF ANY OTHER PRODUCT OR PROCEDURE MAY CAUSE DAMAGE TO ALUMINUM OR PAINTED SURFACES. NOTE THE PRODUCTS USED TO REMOVE SURFACE CONTAMINATION FROM PAINT ARE DESIGNED FOR VEHICLES WHICH HAVE EXPERIENCED EXPOSURE FOR LESS THAN 120 DAYS. VEHICLES THAT EXCEED 120 DAYS OF EXPOSURE MAY REQUIRE THE PROCEDURE BE REPEATED TO RESOLVE THE CONCERN. ONCE THIS PROCEDURE IS COMPLETED, IT MAY BE NECESSARY TO PERFORM POLISHING OR REFINISHING PROCEDURES AFTER VEHICLE INSPECTION. Identification Ferrous metal particles (hot iron dust) are generated by manufacturing facilities, rail shipments, etc. These particles mechanically bond to a vehicle's painted surfaces. Moisture and temperature combine with particles to create a chemical reaction. This reaction creates an acid, causing the iron to corrode and enter the paint surface. Industrial fallout and acid rain generate corrosive compounds that fall on the vehicle's painted surfaces. When subjected to moisture and temperature, chemical compounds are created that etch the paint surface. To assist in identitying surface contamination, use a (Tandy-Radio Shack # 63-851) 30x lighted magnifier. Concern Description Ferrous Metal Light Colored Vehicles: Small orange stains the size of "mechanical pencil lead." The surface is rough to the touch. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 10133 Dark Colored Vehicles: Small white or silver appearing dots with a rainbow ring around the dot. The surface is rough to the touch. Industrial Fallout Water spots with ferrous metal are present and the surface is rough to the touch. Acid Rain/Etching ^ Surface will exhibit irregular discolored spotting. ^ Dark colored vehicles may exhibit cloudy or graying spots where the acid has begun to etch the paint. ^ Extreme cases of etching will be visible and may be felt. Decontamination Procedure Use Ford Acid Neutralizer, Alkaline Neutralizer, and Detail Wash to decontaminate and neutralize the paint surface. Perform the procedure only on vehicle when the paint surface temperature is cool. Follow the step-by-step procedure listed below to perform this service operation. 1. Rinse off dust, dirt, and debris with cold water. Flush liberally. 2. Prepare Acid Neutralizer by mixing 8 parts of water to 1 part Acid Neutralizer in a bucket. 3. Use a clean wash mitt and apply mixture of Acid Neutralizer to the entire vehicle starting at the top of the vehicle working toward the side. Keep the vehicle wet with solution, lightly agitating for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. NOTE USE A SEPARATE MITT FOR EACH PRODUCT. DO NOT INTERMIX MITTS. 4. Rinse the vehicle thoroughly with cold water to remove Acid Neutralizer. 5. Dry only the horizontal surfaces of the vehicle at this time. Do not dry glass. 6. Alkaline Neutralizer is ready to use. Do not mix with water. Pour the contents into a dispenser squirt bottle. Squirt Alkaline Neutralizer directly onto a clean wash mitt. Do not spray Alkaline Neutralizer on the painted surface. Apply the product to the vehicle, keeping the areas wet and lightly agitated for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. 7. Rinse the vehicle thoroughly with cold water. 8. Prepare Detail Wash by mixing 29.5 mL (1 ounce) of Detail Wash to 3.7L (1 gallon) of water. 9. Shampoo the vehicle with Detail Wash using a clean wash mitt. Rinse the vehicle with cold water and dry the vehicle completely. NOTE DETAIL WASH IS A HEAVY DUTY NEUTRAL SHAMPOO CONCENTRATE (pH 7) AND MAY BE USED FOR HAND CAR WASHING OR IN AUTOMATIC CAR WASH SYSTEMS. Surface Correction Following Decontam./Neutralization 1. Visually inspect paint surface for evidence of removal of ferrous metal particles and water spots. NOTE ACID RAIN DISCOLORING OR ETCHING WILL REQUIRE ADDITIONAL PROCEDURES DEPENDENT ON DEPTH OF DAMAGE; POLISHING, BUFFING, COLOR SANDING, OR IN EXTREME CASES, REFINISHING. 2. Do Not Intermix Buffing Products. Use only one manufacturer's products. 3. Always follow the manufacturer's product usage sequence. Use the appropriate recommended pad at recommended buffing speeds as specified by the product manufacturer. NOTE WHEN ATTEMPTING TO AFFECT A REPAIR BY BUFFING, POLISHING, OR COLOR SANDING, DO NOT REMOVE AN EXCESS OF 0.3 MIL OF PAINT FILM OR REFINISHING WILL BE REQUIRED. USE OF AN ELECTRONIC MIL GAUGE (ROTUNDA 164-R4025) IS HIGHLY RECOMMENDED TO INSURE CONTROL OF PAINT FILM REMOVAL. 4. Use a dual action sander with a Velcro backing plate and a foam pad to fine polish and remove any swirls created by a rotary buffer or pad. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 10134 5. Use an alcohol and water mixture (1 to 1 ratio) to clean the buffed areas and to verify removal of scratches and swirls before application of the final polish. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture Technical Service Bulletin # 99-12-10 Date: 990614 Paint - Rough Texture Article No. 99-12-10 06/14/99 ^ PAINT - IRON PARTICLE REMOVAL - INDUSTRIAL FALLOUT - ACID RAIN NEUTRALIZATION ^ PAINT - ROUGH TEXTURE/FERROUS METAL CONTAMINATION - ACID RAIN DISCOLORATION OR ETCHING FORD: 1996-1997 ASPIRE, PROBE, THUNDERBIRD 1996-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1996-1997 COUGAR 1996-1998 MARK VIII 1996-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR LIGHT TRUCK: 1996 BRONCO 1996-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1996-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES MEDIUM/HEAVY TRUCK: 1996-1997 CARGO SERIES 1996-1998 AEROMAX, F SERIES, LOUISVILLE This TSB article is being republished in its entirety to add vehicles and model years, and to revise the procedure to use Ford brand service parts. ISSUE Ford Motor Company has released a private labeled material to be used for iron particle/acid rain service repairs. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 10140 ACTION To remove these particles/contaminates, use ONLY the following products and procedure. No polishing, compounding, color sanding, or repainting should be done before this procedure is performed. This procedure uses products that are acidic, alkaline, and neutral and must be properly mixed and used in their specific order. Refer to the following Service Procedure for details. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 10141 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-21-3 WARRANTY STATUS: Eligible Under The Provisions Of 12 Month/12,000 Mile Basic Warranty Coverage OPERATION DESCRIPTION TIME 991210A Decontaminate And 0.6 Hr. Surface Correction (Aspire, F-450/550, And Cargo) 991210B Decontaminate And 0.7 Hr. Surface Correction (Escort ZX2, Ranger Regular Cab, Probe, Bronco, And Aerostar) 991210C Decontaminate And 0.8 Hr. Surface Correct (Escort/Tracer, Escort/Tracer Wagon, Contour/Mystique, Mustang Convertible/Convertible OT, Taurus/Sable Sedan Or Wagon, 1996-1998 Villager, And 1999 Cougar) 991210D Decontaminate And 0.8 Hr. Surface Correction (F-Series And 1996-97 Thunderbird/Cougar) 991210E Decontaminate And 0.8 Hr. Surface Correction (Ranger SuperCab/Splash, F-150/250 6Ft Bed - Regular Cab/Flare Side Regular Cab, F-250/350 SD 6Ft Bed - Regular Cab, F-450/550 Crew Cab, And Louisville/AeroMax) 991210F Decontaminate And 0.9 Hr. Surface Correction (Mustang Coupe/Coupe GT, Continental, Mark VIII, Ranger Splash SuperCab, Explorer 2-Door, And 1999 Villager) 991210G Decontaminate And 0.9 Hr. Surface Correction (F-150/250 6Ft Bed - SuperCab/8Ft Bed - Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 10142 Regular Cab/Flare Side - SuperCab, And F-250/350 SD 6Ff Bed - SuperCab/8Ft Bed - Regular Cab) 991210H Decontaminate And 1.0 Hr. Surface Correction (Crown Victoria/Grand Marquis, Town Car, Windstar, Explorer 4-Door, And Mountaineer) 9912101 Decontaminate And 1.0 Hr. Surface Correction (F-150/250 8Ft Bed - SuperCab, F-250/350 SD 6Ft Bed - Crew Cab/8Ft Bed SuperCab/8Ft Bed - Crew Cab, And Expedition/Navigator) 991210J Decontaminate And 1.2 Hrs. Surface Correction (Econoline Wagon/Wagon Super-V) 991210k Decontaminate And 1.3 Hrs. Surface Correction (Econoline Cargo) 991210L Decontaminate And 1.4 Hrs. Surface Correction (Econoline Cargo Super-V) DEALER CODING CONDITION BASIC PART NO. CODE ENTRE C8 OASIS CODES: 106000,190000 Service Procedure NOTE ANY CHANGES TO THIS PROCEDURE WILL CAUSE AN INCOMPLETE OR UNSATISFACTORY REPAIR. THE USE OF ANY OTHER PRODUCT OR PROCEDURE MAY CAUSE DAMAGE TO ALUMINUM OR PAINTED SURFACES. NOTE THE PRODUCTS USED TO REMOVE SURFACE CONTAMINATION FROM PAINT ARE DESIGNED FOR VEHICLES WHICH HAVE EXPERIENCED EXPOSURE FOR LESS THAN 120 DAYS. VEHICLES THAT EXCEED 120 DAYS OF EXPOSURE MAY REQUIRE THE PROCEDURE BE REPEATED TO RESOLVE THE CONCERN. ONCE THIS PROCEDURE IS COMPLETED, IT MAY BE NECESSARY TO PERFORM POLISHING OR REFINISHING PROCEDURES AFTER VEHICLE INSPECTION. Identification Ferrous metal particles (hot iron dust) are generated by manufacturing facilities, rail shipments, etc. These particles mechanically bond to a vehicle's painted surfaces. Moisture and temperature combine with particles to create a chemical reaction. This reaction creates an acid, causing the iron to corrode and enter the paint surface. Industrial fallout and acid rain generate corrosive compounds that fall on the vehicle's painted surfaces. When subjected to moisture and temperature, chemical compounds are created that etch the paint surface. To assist in identitying surface contamination, use a (Tandy-Radio Shack # 63-851) 30x lighted magnifier. Concern Description Ferrous Metal Light Colored Vehicles: Small orange stains the size of "mechanical pencil lead." The surface is rough to the touch. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 10143 Dark Colored Vehicles: Small white or silver appearing dots with a rainbow ring around the dot. The surface is rough to the touch. Industrial Fallout Water spots with ferrous metal are present and the surface is rough to the touch. Acid Rain/Etching ^ Surface will exhibit irregular discolored spotting. ^ Dark colored vehicles may exhibit cloudy or graying spots where the acid has begun to etch the paint. ^ Extreme cases of etching will be visible and may be felt. Decontamination Procedure Use Ford Acid Neutralizer, Alkaline Neutralizer, and Detail Wash to decontaminate and neutralize the paint surface. Perform the procedure only on vehicle when the paint surface temperature is cool. Follow the step-by-step procedure listed below to perform this service operation. 1. Rinse off dust, dirt, and debris with cold water. Flush liberally. 2. Prepare Acid Neutralizer by mixing 8 parts of water to 1 part Acid Neutralizer in a bucket. 3. Use a clean wash mitt and apply mixture of Acid Neutralizer to the entire vehicle starting at the top of the vehicle working toward the side. Keep the vehicle wet with solution, lightly agitating for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. NOTE USE A SEPARATE MITT FOR EACH PRODUCT. DO NOT INTERMIX MITTS. 4. Rinse the vehicle thoroughly with cold water to remove Acid Neutralizer. 5. Dry only the horizontal surfaces of the vehicle at this time. Do not dry glass. 6. Alkaline Neutralizer is ready to use. Do not mix with water. Pour the contents into a dispenser squirt bottle. Squirt Alkaline Neutralizer directly onto a clean wash mitt. Do not spray Alkaline Neutralizer on the painted surface. Apply the product to the vehicle, keeping the areas wet and lightly agitated for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. 7. Rinse the vehicle thoroughly with cold water. 8. Prepare Detail Wash by mixing 29.5 mL (1 ounce) of Detail Wash to 3.7L (1 gallon) of water. 9. Shampoo the vehicle with Detail Wash using a clean wash mitt. Rinse the vehicle with cold water and dry the vehicle completely. NOTE DETAIL WASH IS A HEAVY DUTY NEUTRAL SHAMPOO CONCENTRATE (pH 7) AND MAY BE USED FOR HAND CAR WASHING OR IN AUTOMATIC CAR WASH SYSTEMS. Surface Correction Following Decontam./Neutralization 1. Visually inspect paint surface for evidence of removal of ferrous metal particles and water spots. NOTE ACID RAIN DISCOLORING OR ETCHING WILL REQUIRE ADDITIONAL PROCEDURES DEPENDENT ON DEPTH OF DAMAGE; POLISHING, BUFFING, COLOR SANDING, OR IN EXTREME CASES, REFINISHING. 2. Do Not Intermix Buffing Products. Use only one manufacturer's products. 3. Always follow the manufacturer's product usage sequence. Use the appropriate recommended pad at recommended buffing speeds as specified by the product manufacturer. NOTE WHEN ATTEMPTING TO AFFECT A REPAIR BY BUFFING, POLISHING, OR COLOR SANDING, DO NOT REMOVE AN EXCESS OF 0.3 MIL OF PAINT FILM OR REFINISHING WILL BE REQUIRED. USE OF AN ELECTRONIC MIL GAUGE (ROTUNDA 164-R4025) IS HIGHLY RECOMMENDED TO INSURE CONTROL OF PAINT FILM REMOVAL. 4. Use a dual action sander with a Velcro backing plate and a foam pad to fine polish and remove any swirls created by a rotary buffer or pad. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 99-12-10 > Jun > 99 > Paint - Rough Texture > Page 10144 5. Use an alcohol and water mixture (1 to 1 ratio) to clean the buffed areas and to verify removal of scratches and swirls before application of the final polish. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 10145 Paint: By Symptom Technical Service Bulletin # 99-12-10 Date: 990614 Paint - Rough Texture Article No. 99-12-10 06/14/99 ^ PAINT - IRON PARTICLE REMOVAL - INDUSTRIAL FALLOUT - ACID RAIN NEUTRALIZATION ^ PAINT - ROUGH TEXTURE/FERROUS METAL CONTAMINATION - ACID RAIN DISCOLORATION OR ETCHING FORD: 1996-1997 ASPIRE, PROBE, THUNDERBIRD 1996-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1996-1997 COUGAR 1996-1998 MARK VIII 1996-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR LIGHT TRUCK: 1996 BRONCO 1996-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1996-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES MEDIUM/HEAVY TRUCK: 1996-1997 CARGO SERIES 1996-1998 AEROMAX, F SERIES, LOUISVILLE This TSB article is being republished in its entirety to add vehicles and model years, and to revise the procedure to use Ford brand service parts. ISSUE Ford Motor Company has released a private labeled material to be used for iron particle/acid rain service repairs. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 10146 ACTION To remove these particles/contaminates, use ONLY the following products and procedure. No polishing, compounding, color sanding, or repainting should be done before this procedure is performed. This procedure uses products that are acidic, alkaline, and neutral and must be properly mixed and used in their specific order. Refer to the following Service Procedure for details. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 10147 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-21-3 WARRANTY STATUS: Eligible Under The Provisions Of 12 Month/12,000 Mile Basic Warranty Coverage OPERATION DESCRIPTION TIME 991210A Decontaminate And 0.6 Hr. Surface Correction (Aspire, F-450/550, And Cargo) 991210B Decontaminate And 0.7 Hr. Surface Correction (Escort ZX2, Ranger Regular Cab, Probe, Bronco, And Aerostar) 991210C Decontaminate And 0.8 Hr. Surface Correct (Escort/Tracer, Escort/Tracer Wagon, Contour/Mystique, Mustang Convertible/Convertible OT, Taurus/Sable Sedan Or Wagon, 1996-1998 Villager, And 1999 Cougar) 991210D Decontaminate And 0.8 Hr. Surface Correction (F-Series And 1996-97 Thunderbird/Cougar) 991210E Decontaminate And 0.8 Hr. Surface Correction (Ranger SuperCab/Splash, F-150/250 6Ft Bed - Regular Cab/Flare Side Regular Cab, F-250/350 SD 6Ft Bed - Regular Cab, F-450/550 Crew Cab, And Louisville/AeroMax) 991210F Decontaminate And 0.9 Hr. Surface Correction (Mustang Coupe/Coupe GT, Continental, Mark VIII, Ranger Splash SuperCab, Explorer 2-Door, And 1999 Villager) 991210G Decontaminate And 0.9 Hr. Surface Correction (F-150/250 6Ft Bed - SuperCab/8Ft Bed - Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 10148 Regular Cab/Flare Side - SuperCab, And F-250/350 SD 6Ff Bed - SuperCab/8Ft Bed - Regular Cab) 991210H Decontaminate And 1.0 Hr. Surface Correction (Crown Victoria/Grand Marquis, Town Car, Windstar, Explorer 4-Door, And Mountaineer) 9912101 Decontaminate And 1.0 Hr. Surface Correction (F-150/250 8Ft Bed - SuperCab, F-250/350 SD 6Ft Bed - Crew Cab/8Ft Bed SuperCab/8Ft Bed - Crew Cab, And Expedition/Navigator) 991210J Decontaminate And 1.2 Hrs. Surface Correction (Econoline Wagon/Wagon Super-V) 991210k Decontaminate And 1.3 Hrs. Surface Correction (Econoline Cargo) 991210L Decontaminate And 1.4 Hrs. Surface Correction (Econoline Cargo Super-V) DEALER CODING CONDITION BASIC PART NO. CODE ENTRE C8 OASIS CODES: 106000,190000 Service Procedure NOTE ANY CHANGES TO THIS PROCEDURE WILL CAUSE AN INCOMPLETE OR UNSATISFACTORY REPAIR. THE USE OF ANY OTHER PRODUCT OR PROCEDURE MAY CAUSE DAMAGE TO ALUMINUM OR PAINTED SURFACES. NOTE THE PRODUCTS USED TO REMOVE SURFACE CONTAMINATION FROM PAINT ARE DESIGNED FOR VEHICLES WHICH HAVE EXPERIENCED EXPOSURE FOR LESS THAN 120 DAYS. VEHICLES THAT EXCEED 120 DAYS OF EXPOSURE MAY REQUIRE THE PROCEDURE BE REPEATED TO RESOLVE THE CONCERN. ONCE THIS PROCEDURE IS COMPLETED, IT MAY BE NECESSARY TO PERFORM POLISHING OR REFINISHING PROCEDURES AFTER VEHICLE INSPECTION. Identification Ferrous metal particles (hot iron dust) are generated by manufacturing facilities, rail shipments, etc. These particles mechanically bond to a vehicle's painted surfaces. Moisture and temperature combine with particles to create a chemical reaction. This reaction creates an acid, causing the iron to corrode and enter the paint surface. Industrial fallout and acid rain generate corrosive compounds that fall on the vehicle's painted surfaces. When subjected to moisture and temperature, chemical compounds are created that etch the paint surface. To assist in identitying surface contamination, use a (Tandy-Radio Shack # 63-851) 30x lighted magnifier. Concern Description Ferrous Metal Light Colored Vehicles: Small orange stains the size of "mechanical pencil lead." The surface is rough to the touch. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 10149 Dark Colored Vehicles: Small white or silver appearing dots with a rainbow ring around the dot. The surface is rough to the touch. Industrial Fallout Water spots with ferrous metal are present and the surface is rough to the touch. Acid Rain/Etching ^ Surface will exhibit irregular discolored spotting. ^ Dark colored vehicles may exhibit cloudy or graying spots where the acid has begun to etch the paint. ^ Extreme cases of etching will be visible and may be felt. Decontamination Procedure Use Ford Acid Neutralizer, Alkaline Neutralizer, and Detail Wash to decontaminate and neutralize the paint surface. Perform the procedure only on vehicle when the paint surface temperature is cool. Follow the step-by-step procedure listed below to perform this service operation. 1. Rinse off dust, dirt, and debris with cold water. Flush liberally. 2. Prepare Acid Neutralizer by mixing 8 parts of water to 1 part Acid Neutralizer in a bucket. 3. Use a clean wash mitt and apply mixture of Acid Neutralizer to the entire vehicle starting at the top of the vehicle working toward the side. Keep the vehicle wet with solution, lightly agitating for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. NOTE USE A SEPARATE MITT FOR EACH PRODUCT. DO NOT INTERMIX MITTS. 4. Rinse the vehicle thoroughly with cold water to remove Acid Neutralizer. 5. Dry only the horizontal surfaces of the vehicle at this time. Do not dry glass. 6. Alkaline Neutralizer is ready to use. Do not mix with water. Pour the contents into a dispenser squirt bottle. Squirt Alkaline Neutralizer directly onto a clean wash mitt. Do not spray Alkaline Neutralizer on the painted surface. Apply the product to the vehicle, keeping the areas wet and lightly agitated for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. 7. Rinse the vehicle thoroughly with cold water. 8. Prepare Detail Wash by mixing 29.5 mL (1 ounce) of Detail Wash to 3.7L (1 gallon) of water. 9. Shampoo the vehicle with Detail Wash using a clean wash mitt. Rinse the vehicle with cold water and dry the vehicle completely. NOTE DETAIL WASH IS A HEAVY DUTY NEUTRAL SHAMPOO CONCENTRATE (pH 7) AND MAY BE USED FOR HAND CAR WASHING OR IN AUTOMATIC CAR WASH SYSTEMS. Surface Correction Following Decontam./Neutralization 1. Visually inspect paint surface for evidence of removal of ferrous metal particles and water spots. NOTE ACID RAIN DISCOLORING OR ETCHING WILL REQUIRE ADDITIONAL PROCEDURES DEPENDENT ON DEPTH OF DAMAGE; POLISHING, BUFFING, COLOR SANDING, OR IN EXTREME CASES, REFINISHING. 2. Do Not Intermix Buffing Products. Use only one manufacturer's products. 3. Always follow the manufacturer's product usage sequence. Use the appropriate recommended pad at recommended buffing speeds as specified by the product manufacturer. NOTE WHEN ATTEMPTING TO AFFECT A REPAIR BY BUFFING, POLISHING, OR COLOR SANDING, DO NOT REMOVE AN EXCESS OF 0.3 MIL OF PAINT FILM OR REFINISHING WILL BE REQUIRED. USE OF AN ELECTRONIC MIL GAUGE (ROTUNDA 164-R4025) IS HIGHLY RECOMMENDED TO INSURE CONTROL OF PAINT FILM REMOVAL. 4. Use a dual action sander with a Velcro backing plate and a foam pad to fine polish and remove any swirls created by a rotary buffer or pad. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 10150 5. Use an alcohol and water mixture (1 to 1 ratio) to clean the buffed areas and to verify removal of scratches and swirls before application of the final polish. Technical Service Bulletin # 99-12-10 Date: 990614 Paint - Rough Texture Article No. 99-12-10 06/14/99 ^ PAINT - IRON PARTICLE REMOVAL - INDUSTRIAL FALLOUT - ACID RAIN NEUTRALIZATION ^ PAINT - ROUGH TEXTURE/FERROUS METAL CONTAMINATION - ACID RAIN DISCOLORATION OR ETCHING FORD: 1996-1997 ASPIRE, PROBE, THUNDERBIRD 1996-1999 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1996-1997 COUGAR 1996-1998 MARK VIII 1996-1999 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER 1999 COUGAR LIGHT TRUCK: 1996 BRONCO 1996-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1996-1999 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER, WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES MEDIUM/HEAVY TRUCK: 1996-1997 CARGO SERIES 1996-1998 AEROMAX, F SERIES, LOUISVILLE This TSB article is being republished in its entirety to add vehicles and model years, and to revise the procedure to use Ford brand service parts. ISSUE Ford Motor Company has released a private labeled material to be used for iron particle/acid rain service repairs. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 10151 ACTION To remove these particles/contaminates, use ONLY the following products and procedure. No polishing, compounding, color sanding, or repainting should be done before this procedure is performed. This procedure uses products that are acidic, alkaline, and neutral and must be properly mixed and used in their specific order. Refer to the following Service Procedure for details. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 10152 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-21-3 WARRANTY STATUS: Eligible Under The Provisions Of 12 Month/12,000 Mile Basic Warranty Coverage OPERATION DESCRIPTION TIME 991210A Decontaminate And 0.6 Hr. Surface Correction (Aspire, F-450/550, And Cargo) 991210B Decontaminate And 0.7 Hr. Surface Correction (Escort ZX2, Ranger Regular Cab, Probe, Bronco, And Aerostar) 991210C Decontaminate And 0.8 Hr. Surface Correct (Escort/Tracer, Escort/Tracer Wagon, Contour/Mystique, Mustang Convertible/Convertible OT, Taurus/Sable Sedan Or Wagon, 1996-1998 Villager, And 1999 Cougar) 991210D Decontaminate And 0.8 Hr. Surface Correction (F-Series And 1996-97 Thunderbird/Cougar) 991210E Decontaminate And 0.8 Hr. Surface Correction (Ranger SuperCab/Splash, F-150/250 6Ft Bed - Regular Cab/Flare Side Regular Cab, F-250/350 SD 6Ft Bed - Regular Cab, F-450/550 Crew Cab, And Louisville/AeroMax) 991210F Decontaminate And 0.9 Hr. Surface Correction (Mustang Coupe/Coupe GT, Continental, Mark VIII, Ranger Splash SuperCab, Explorer 2-Door, And 1999 Villager) 991210G Decontaminate And 0.9 Hr. Surface Correction (F-150/250 6Ft Bed - SuperCab/8Ft Bed - Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 10153 Regular Cab/Flare Side - SuperCab, And F-250/350 SD 6Ff Bed - SuperCab/8Ft Bed - Regular Cab) 991210H Decontaminate And 1.0 Hr. Surface Correction (Crown Victoria/Grand Marquis, Town Car, Windstar, Explorer 4-Door, And Mountaineer) 9912101 Decontaminate And 1.0 Hr. Surface Correction (F-150/250 8Ft Bed - SuperCab, F-250/350 SD 6Ft Bed - Crew Cab/8Ft Bed SuperCab/8Ft Bed - Crew Cab, And Expedition/Navigator) 991210J Decontaminate And 1.2 Hrs. Surface Correction (Econoline Wagon/Wagon Super-V) 991210k Decontaminate And 1.3 Hrs. Surface Correction (Econoline Cargo) 991210L Decontaminate And 1.4 Hrs. Surface Correction (Econoline Cargo Super-V) DEALER CODING CONDITION BASIC PART NO. CODE ENTRE C8 OASIS CODES: 106000,190000 Service Procedure NOTE ANY CHANGES TO THIS PROCEDURE WILL CAUSE AN INCOMPLETE OR UNSATISFACTORY REPAIR. THE USE OF ANY OTHER PRODUCT OR PROCEDURE MAY CAUSE DAMAGE TO ALUMINUM OR PAINTED SURFACES. NOTE THE PRODUCTS USED TO REMOVE SURFACE CONTAMINATION FROM PAINT ARE DESIGNED FOR VEHICLES WHICH HAVE EXPERIENCED EXPOSURE FOR LESS THAN 120 DAYS. VEHICLES THAT EXCEED 120 DAYS OF EXPOSURE MAY REQUIRE THE PROCEDURE BE REPEATED TO RESOLVE THE CONCERN. ONCE THIS PROCEDURE IS COMPLETED, IT MAY BE NECESSARY TO PERFORM POLISHING OR REFINISHING PROCEDURES AFTER VEHICLE INSPECTION. Identification Ferrous metal particles (hot iron dust) are generated by manufacturing facilities, rail shipments, etc. These particles mechanically bond to a vehicle's painted surfaces. Moisture and temperature combine with particles to create a chemical reaction. This reaction creates an acid, causing the iron to corrode and enter the paint surface. Industrial fallout and acid rain generate corrosive compounds that fall on the vehicle's painted surfaces. When subjected to moisture and temperature, chemical compounds are created that etch the paint surface. To assist in identitying surface contamination, use a (Tandy-Radio Shack # 63-851) 30x lighted magnifier. Concern Description Ferrous Metal Light Colored Vehicles: Small orange stains the size of "mechanical pencil lead." The surface is rough to the touch. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 10154 Dark Colored Vehicles: Small white or silver appearing dots with a rainbow ring around the dot. The surface is rough to the touch. Industrial Fallout Water spots with ferrous metal are present and the surface is rough to the touch. Acid Rain/Etching ^ Surface will exhibit irregular discolored spotting. ^ Dark colored vehicles may exhibit cloudy or graying spots where the acid has begun to etch the paint. ^ Extreme cases of etching will be visible and may be felt. Decontamination Procedure Use Ford Acid Neutralizer, Alkaline Neutralizer, and Detail Wash to decontaminate and neutralize the paint surface. Perform the procedure only on vehicle when the paint surface temperature is cool. Follow the step-by-step procedure listed below to perform this service operation. 1. Rinse off dust, dirt, and debris with cold water. Flush liberally. 2. Prepare Acid Neutralizer by mixing 8 parts of water to 1 part Acid Neutralizer in a bucket. 3. Use a clean wash mitt and apply mixture of Acid Neutralizer to the entire vehicle starting at the top of the vehicle working toward the side. Keep the vehicle wet with solution, lightly agitating for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. NOTE USE A SEPARATE MITT FOR EACH PRODUCT. DO NOT INTERMIX MITTS. 4. Rinse the vehicle thoroughly with cold water to remove Acid Neutralizer. 5. Dry only the horizontal surfaces of the vehicle at this time. Do not dry glass. 6. Alkaline Neutralizer is ready to use. Do not mix with water. Pour the contents into a dispenser squirt bottle. Squirt Alkaline Neutralizer directly onto a clean wash mitt. Do not spray Alkaline Neutralizer on the painted surface. Apply the product to the vehicle, keeping the areas wet and lightly agitated for 5 to 7 minutes. For vehicles with severe conditions, work the product for up to 8 minutes. 7. Rinse the vehicle thoroughly with cold water. 8. Prepare Detail Wash by mixing 29.5 mL (1 ounce) of Detail Wash to 3.7L (1 gallon) of water. 9. Shampoo the vehicle with Detail Wash using a clean wash mitt. Rinse the vehicle with cold water and dry the vehicle completely. NOTE DETAIL WASH IS A HEAVY DUTY NEUTRAL SHAMPOO CONCENTRATE (pH 7) AND MAY BE USED FOR HAND CAR WASHING OR IN AUTOMATIC CAR WASH SYSTEMS. Surface Correction Following Decontam./Neutralization 1. Visually inspect paint surface for evidence of removal of ferrous metal particles and water spots. NOTE ACID RAIN DISCOLORING OR ETCHING WILL REQUIRE ADDITIONAL PROCEDURES DEPENDENT ON DEPTH OF DAMAGE; POLISHING, BUFFING, COLOR SANDING, OR IN EXTREME CASES, REFINISHING. 2. Do Not Intermix Buffing Products. Use only one manufacturer's products. 3. Always follow the manufacturer's product usage sequence. Use the appropriate recommended pad at recommended buffing speeds as specified by the product manufacturer. NOTE WHEN ATTEMPTING TO AFFECT A REPAIR BY BUFFING, POLISHING, OR COLOR SANDING, DO NOT REMOVE AN EXCESS OF 0.3 MIL OF PAINT FILM OR REFINISHING WILL BE REQUIRED. USE OF AN ELECTRONIC MIL GAUGE (ROTUNDA 164-R4025) IS HIGHLY RECOMMENDED TO INSURE CONTROL OF PAINT FILM REMOVAL. 4. Use a dual action sander with a Velcro backing plate and a foam pad to fine polish and remove any swirls created by a rotary buffer or pad. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > Page 10155 5. Use an alcohol and water mixture (1 to 1 ratio) to clean the buffed areas and to verify removal of scratches and swirls before application of the final polish. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams Keyless Entry Module: Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Diagrams > Page 10160 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Component Information > Technical Service Bulletins > Battery Saver Relay - Malfunction Sunroof / Moonroof: Technical Service Bulletins Battery Saver Relay - Malfunction Article No. 00-19-2 09/18/00 ^ LAMP - COURTESY, GLOVE COMPARTMENT, UNDERHOOD, RUNNING BOARD LAMPS INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES ^ POWER WINDOWS - INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES ^ RADIO - INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES ^ REAR WIPER - INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES FORD: 1999-2000 EXPEDITION, F-150, F-250 LD LINCOLN: 1999-2000 NAVIGATOR This article is being republished in its entirety to update the part number. ISSUE A temporary loss of functions controlled by the battery saver relay may occur on some vehicles. These functions may be inoperative for a short period of time after the vehicle has sat unattended for at least 45 minutes. These functions are limited to courtesy and interior/demand lamps, glove compartment, underhood lamps and power windows. Running board lights, moonroof and the rear wiper may be affected on Expedition and Navigator. The radio may also be inoperative during this time on Navigator only. The loss of these features is temporary and can last from a few seconds up to 10-15 minutes. ACTION Replace the Battery Saver Relay (YL3Z-14N089-AA). Refer to the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) for location of this relay. NOTE PERMANENT LOSS OF ANY OF THESE FUNCTIONS SHOULD NOT BE ADDRESSED WITH THIS TSB. FUNCTIONS OTHER THAN THOSE EXPLICITLY MENTIONED ABOVE THAT ARE REPORTED TO BE INOPERATIVE SHOULD NOT BE ADDRESSED WITH THIS TSB. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-8-7 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION / DESCRIPTION / TIME Table Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Component Information > Technical Service Bulletins > Battery Saver Relay - Malfunction > Page 10166 DEALER CODING OASIS CODES: 10200, 204000, 201100, 201200, 202000, 20300, 205000, 207000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Page 10174 Power Seat Switch: Testing and Inspection Component Testing Procedure Component Testing Procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Page 10175 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Page 10176 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Page 10177 Power Seat Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the front seat back recliner handle. 1 Remove the screw. 2 Remove the front seat back recliner handle. 3. Remove the front seat lumbar support knob. 4. Remove the front seat track side shield. 1 Remove the screws. 2 Remove the pin-type retainer. 3 Remove the front seat track side shield. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Page 10178 5. Disconnect the seat regulator control switch from the front seat track side shield. 1 Remove the screws. 2 Disconnect the seat regulator control switch. 6. Disconnect the seat regulator control switch electrical connector and remove the seat regulator control switch. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Page 10179 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 6 km (10 mi) or more to relearn the strategy. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Specifications Seat Cushion: Specifications Front Seat Recliner to Front Seat Cushion Bolts .............................................................................................................................. 44-55 Nm (33-40 ft lbs) Full Bench Front Seat Hinge to Cushion Bolts ................................................................................................................................ 44-55 Nm (33-40 ft lbs) Manual Front Seat Track to Seat Cushion Bolts .............................................................................................................................. 21-29 Nm (16-21 ft lbs) Rear Seat Cushion Latch Striker Nuts .............................................................................................................................................. 44-55 Nm (33-40 ft lbs) 40 Percent Rear Seat Cushion Hinge Bolts ................................................................................................................................... 4.5-7.5 Nm (40-66 in lbs) 40 Percent Rear Seat Cushion Latch and Buckle Bolts .................................................................................................................... 21-29 Nm (16-21 ft lbs) 40 Percent Rear Seat Cushion to Load Floor Bolts ....................................................................................................................... 4.5-7.5 Nm (40-66 in lbs) 40 Percent Rear Seat Cushion Load Floor Screws ........................................................................................................................ 1.5-2.0 Nm (14-17 in lbs) 60 Percent Rear Seat Cushion Hinge Bolts ................................................................................................................................... 4.5-7.5 Nm (40-66 in lbs) 60 Percent Rear Seat Cushion Latch and Buckle Bolts .................................................................................................................... 21-29 Nm (16-21 ft lbs) 60 Percent Rear Seat Cushion Load Floor Screws ....................................................................................................................... 1.5-2.0 Nm (1.1-1.4 ft lbs) 60 Percent Rear Seat Cushion to Load Floor Bolts ................................................................................................................... 8.5-11.5 Nm (75-101 in lbs) 60/40 Split Front Bench Armrest Latch to Seat Cushion Bolts ......................................................................................................................................................... 44-55 Nm (33-40 ft lbs) Mounting Bracket to Seat Cushion Bolts ..................................................................................................................................... 44-55 Nm (33-40 ft lbs) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Installation Seat Cushion: Service and Repair Removal and Installation REMOVAL 1. Open the rear seat to the load floor position. 2. Remove the two bolts. 3. Fold the seat to its original position. 4. Remove the rear seat. 1 Remove the nuts. 2 Remove the bolts. 3 Remove the rear cushion. NOTE: Removing the rear seat cushion requires more than one technician. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Installation > Page 10185 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Installation > Page 10186 Seat Cushion: Service and Repair Disassembly and Assembly Captain's Chair Seat Cushion DISASSEMBLY 1. Disassemble the captain's chair. 2. Unfasten the front seat cushion cover J-clips. 3. Invert the seat cushion trim cover to expose the hog rings. 4. Remove the seat cushion trim cover. 1 Remove the hog rings. 2 Remove the seat cushion trim cover. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Installation > Page 10187 5. Remove the front seat cushion foam pin-type retainer. 6. Remove the front seat cushion foam from the front seat cushion frame. ASSEMBLY 1. Insert the front seat cushion frame into the front seat cushion foam. 2. Install the front seat cushion foam pin-type retainer. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Installation > Page 10188 3. Position the front seat cushion trim cover. 4. Install the hog rings. 5. Position the front seat cushion trim cover. 6. Fasten the front seat cushion trim cover J-clips. 60 Percent Bench Seat Cushion DISASSEMBLY 1. Disassemble the 60 percent front seat. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Installation > Page 10189 2. Unfasten the front seat cushion cover retainers. 3. Remove the five front seat cushion trim cover hog rings and remove the 60 percent front seat cushion trim cover. 4. Separate the front seat cushion frame from the front seat cushion foam. ASSEMBLY 1. To assemble, reverse the disassembly procedure. Front Bench Seat Cushion DISASSEMBLY 1. Disassemble the front bench seat. 2. Unclip the seat cushion trim cover J-clips. 3. Remove the safety belt opening hog rings. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Installation > Page 10190 4. Position the seat cushion trim cover to access the hog rings. 5. Remove the seat cushion trim cover. 1 Remove the hog rings. 2 Remove the seat cushion trim cover. 6. Remove the seat cushion frame from the seat cushion foam. ASSEMBLY 1. To assemble, reverse the disassembly procedure. Rear Seat Cushion DISASSEMBLY 1. Remove the 60 percent rear seat cushion. 1 Remove the six bolts. 2 Remove the 60 percent rear seat cushion. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Installation > Page 10191 2. Remove the 40 percent rear seat cushion. 1 Remove the bolts. 2 Remove the 40 percent rear seat cushion. 3. Remove the LH and RH rear seat riser supports. 1 Remove the six bolts (three on each support). 2 Remove the LH and RH rear seat riser supports. 4. Remove the two bolts and remove the center rear seat riser support. 5. Remove the two rear seat back latch strikers. 1 Remove the nuts. 2 Remove the rear seat back latch strikers. ASSEMBLY 1. Install the two rear seat back latch strikers 1 Position the rear seat back latch strikers. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Installation > Page 10192 2 Install the nuts. 2. Install the LH and RH rear seat riser supports. 1 Position the riser supports. 2 Install the six bolts (three on each support). 3. Position the center rear seat riser support and install the two bolts. 4. Install the 40 percent rear seat cushion. 1 Position the 40 percent rear seat cushion. 2 Install the bolts. ^ Check for proper operation. 5. Install the 60 percent rear seat cushion. 1 Position the 60 percent rear seat cushion. 2 Install the six bolts. ^ Check for proper operation. 40 Percent Rear Seat Cushion DISASSEMBLY Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Installation > Page 10193 1. Remove the 40 percent rear seat cushion panel. 1 Remove the screws. 2 Remove the 40 percent rear seat cushion load floor panel. 2. Unfasten the 40 percent rear seat cushion cover retainers. 3. Remove the three seat cushion hog rings and remove the 40 percent rear seat cushion cover. 4. Separate the 40 percent rear seat cushion foam from the rear seat cushion frame. 5. Remove the 40 percent rear seat hinges. 1 Remove the bolts. 2 Remove the rear seat hinges. 6. Remove the 40 percent rear seat cushion latch and buckle assembly. 1 Remove the bolts. 2 Remove the 40 percent rear seat cushion latch and buckle assembly. ASSEMBLY Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Installation > Page 10194 1. Install the 40 percent rear seat cushion latch and buckle assembly. 1 Position the latch and buckle assembly. 2 Install the bolts. 2. Install the 40 percent rear seat hinges. 1 Position the hinges. 2 Install the bolts. 3. Install the 40 percent rear seat cushion foam into the rear seat cushion frame. 4. Position the 40 percent rear seat cushion cover and install the three hog rings. 5. Install the 40 percent rear seat cushion cover retainers. 6. Install the 40 percent rear seat cushion load floor panel. 1 Position the load floor panel. 2 Install the screws. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Installation > Page 10195 60 Percent Rear Seat Cushion DISASSEMBLY 1. Remove the 60 percent rear seat cushion load floor panel. 1 Remove the screws. 2 Remove the 60 percent rear seat cushion load floor panel. 2. Remove the 60 percent rear seat cushion latch and buckle assembly. 1 Remove the bolts. 2 Remove the 60 percent rear seat cushion latch and buckle assembly. 3. Remove the (A) 60 percent rear seat cushion cover retainers, nine hog rings, and the (B) cover. 4. Separate the 60 percent rear seat cushion foam from the rear seat cushion frame. 5. Remove the 60 percent rear seat hinges. 1 Remove the bolts. 2 Remove the 60 percent rear seat hinges. ASSEMBLY Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Removal and Installation > Page 10196 1. Install the 60 percent rear seat hinges. 1 Position the hinges. 2 Install the bolts. 2. Insert the 60 percent rear seat cushion foam into the rear seat cushion frame. 3. Position the (B) cover and install the (A) 60 percent rear seat cushion cover retainers and the nine hog rings. 4. Install the 60 percent rear seat cushion latch and buckle assembly. 1 Position the latch and buckle assembly. 2 Install the bolts. 5. Install the 60 percent rear seat cushion load floor panel. 1 Position the load floor panel. 2 Install the screws. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Specifications Seat Latch: Specifications 60/40 Split Front Bench Armrest Latch to Armrest Bolts ......................................................................................................................... ........................................ 44-55 Nm (33-40 ft lbs) Latch to Seat Cushion Bolts ......................................................................................................................................................... 44-55 Nm (33-40 ft lbs) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Specifications Seat Track: Specifications Front Seat Riser to Seat Track Nuts ................................................................................................................................................. 44-55 Nm (33-40 ft lbs) Manual Front Seat Track to Seat Cushion Bolts .............................................................................................................................. 21-29 Nm (16-21 ft lbs) Towel Bar to Seat Track Bolts ........................................................................................................................................................... 10-14 Nm (8-10 ft lbs) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Disassembly and Assembly Seat Track: Service and Repair Disassembly and Assembly DISASSEMBLY 1. Remove the seat track. 2. Remove the two front seat riser supports. 1 Remove the four nuts. 2 Remove the two front seat riser supports and the riser bracket. 3. Remove manual seat track release bar. 1 Remove the bolts. 2 If equipped, drill out the rivet. 3 Remove the manual seat track release bar. ASSEMBLY 1. Install manual seat track release bar. 1 Position manual seat track release bar onto the front seat track. 2 Install the three bolts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Disassembly and Assembly > Page 10205 2. Install the two front seat risers. 1 Position the two front seat risers and the riser bracket. 2 Install the four nuts. NOTE: Inspect the seat risers and verify that plastic isolators are in place. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Disassembly and Assembly > Page 10206 Seat Track: Service and Repair Manual Seat Track REMOVAL 1. Remove the front seat. 2. Remove the seat track to seat cushion front bolts. 1 Position the seat track rearward. 2 Remove the seat track to seat cushion front bolts. 3. Remove the seat track assembly. 1 Position the seat track forward. 2 Remove the seat track rear bolts. 3 Remove the seat track assembly. INSTALLATION 1. Install the seat track. 1 Position the seat track. 2 Loosely install the seat track rear bolts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Disassembly and Assembly > Page 10207 2. Install the seat track front bolts. 1 Position the seat track rearward. 2 Install the seat track front bolts. 3. Tighten the seat track rear bolts. 4. Install the front seat. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Disassembly and Assembly > Page 10208 Seat Track: Service and Repair Power Seat Track REMOVAL 1. Raise the power seat to its maximum height. 2. Disconnect the battery ground cable. 3. Remove the captain's chair. 4. Disconnect the seat regulator control switch electrical connector. 5. Remove the power seat track. 1 Remove the bolts. 2 Remove the seat track. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Disassembly and Assembly > Page 10209 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Revised Article No. 01-21-6 10/29/01 ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE MERCURY HOOD LAMP SWITCH FORD: 1987-1995 TAURUS 1988-1991 CROWN VICTORIA 1989 THUNDERBIRD 1989-1996 MUSTANG 1994-1996 THUNDERBIRD 1990 BRONCO II 1990-1996 RANGER 1991-1996 BRONCO 1994-2001 EXPLORER 1997-2001 F-150 2000-2001 EXCURSION 2002 EXPEDITION LINCOLN: 1989-1994 CONTINENTAL 1990-1992 MARK VII 1990-1996 TOWN CAR 1993-1995 MARK VIII 2002 NAVIGATOR MERCURY: 1987-1995 SABLE 1988-1991 GRAND MARQUIS 1989 COUGAR 1994-1996 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is to provide information on replacement hood lamp switches. The 27 degree Mercury style hood switches will no longer be available. Replacement 27 degree Mechanical switches will be available as a service replacement. ACTION For vehicles requiring hood lamp switch replacement, replace the 27 degree Mercury switch with new 27 degree Mechanical switch. Replace hood lamp switch per the appropriate model year Workshop Manual as needed. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised > Page 10216 OASIS CODES: 201000, 201200 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Left Power Door Lock Switch Power Door Lock Switch: Diagrams Left Power Door Lock Switch Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Left Power Door Lock Switch > Page 10221 Power Door Lock Switch: Diagrams Right Front Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > With Remote Anti-Theft Personality Power Door Lock Switch: Testing and Inspection With Remote Anti-Theft Personality Left Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > With Remote Anti-Theft Personality > Page 10224 Schematic Right Component Testing Procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > With Remote Anti-Theft Personality > Page 10225 Terminals Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > With Remote Anti-Theft Personality > Page 10226 Power Door Lock Switch: Testing and Inspection Without Remote Anti-Theft Personality Left Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > With Remote Anti-Theft Personality > Page 10227 Schematic Right Component Testing Procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Testing and Inspection > With Remote Anti-Theft Personality > Page 10228 Terminals Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Left Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Left > Page 10233 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Left > Page 10234 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Component Testing Procedure Power Mirror Switch: Testing and Inspection Component Testing Procedure Component Testing Procedure (part 1 Of 2) Component Testing Procedure (part 2 Of 2) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Component Testing Procedure > Page 10237 Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Component Testing Procedure > Page 10238 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Testing and Inspection > Component Testing Procedure > Page 10239 Power Mirror Switch: Testing and Inspection Component Tests OUTSIDE REAR VIEW MIRROR CONTROL SWITCH Measure the resistance between the following terminals while pressing the switch in the requested directions: If the resistance is less than 5 ohms in each direction, return to the originating pinpoint test otherwise, replace the switch. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 10243 Power Seat Switch: Testing and Inspection Component Testing Procedure Component Testing Procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 10244 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 10245 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 10246 Power Seat Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the front seat back recliner handle. 1 Remove the screw. 2 Remove the front seat back recliner handle. 3. Remove the front seat lumbar support knob. 4. Remove the front seat track side shield. 1 Remove the screws. 2 Remove the pin-type retainer. 3 Remove the front seat track side shield. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 10247 5. Disconnect the seat regulator control switch from the front seat track side shield. 1 Remove the screws. 2 Disconnect the seat regulator control switch. 6. Disconnect the seat regulator control switch electrical connector and remove the seat regulator control switch. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Diagrams > Page 10248 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 6 km (10 mi) or more to relearn the strategy. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Hinge > Component Information > Technical Service Bulletins > Customer Interest for Tailgate Hinge: > 02-3-5 > Feb > 02 > Tailgate - Squeaking/Binding Condition Tailgate Hinge: Customer Interest Tailgate - Squeaking/Binding Condition Article No. 02-3-5 02/18/02 ^ BODY - "SQUEAK" OR BIND FROM TAILGATE ^ NOISE - "SQUEAK" OR BIND FROM TAILGATE FORD: 1997-1998 F SUPER DUTY 1997-2002 F-150, RANGER 1999-2002 SUPER DUTY F SERIES 2001-2002 EXPLORER SPORT TRAC ISSUE Some vehicles may exhibit a "Squeak" or Bind condition of the Tailgate. This may be caused by the grease on the tailgate hinges that may wash out prematurely causing a squeak or binding condition. ACTION Verify condition. Apply Silicone grease to correct the condition. Refer the the following Service Procedure for details. SERVICE PROCEDURE 1. Remove tail gate from the vehicle. 2. Remove plastic inserts from tail gate hinge cups. 3. Clean inside of hinge cups. 4. Apply grease (use only XG-3), to all inside surfaces of right and left side hinge cups and right and left side body side pins (Figure 1) and re-install plastic inserts into tail gate. 5. Reinstall the tail gate Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Hinge > Component Information > Technical Service Bulletins > Customer Interest for Tailgate Hinge: > 02-3-5 > Feb > 02 > Tailgate - Squeaking/Binding Condition > Page 10258 Parts Block OTHER APPLICABLE ARTICLES: NONE OPERATION DESCRIPTION TIME 020305A Apply Grease As 0.3 Hr. Instructed In Service Procedure DEALER CODING CONDITION BASIC PART NO. CODE 99430B22 41 OASIS CODES: 111000,112600, 702000, 702200 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Hinge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Hinge: > 02-3-5 > Feb > 02 > Tailgate - Squeaking/Binding Condition Tailgate Hinge: All Technical Service Bulletins Tailgate - Squeaking/Binding Condition Article No. 02-3-5 02/18/02 ^ BODY - "SQUEAK" OR BIND FROM TAILGATE ^ NOISE - "SQUEAK" OR BIND FROM TAILGATE FORD: 1997-1998 F SUPER DUTY 1997-2002 F-150, RANGER 1999-2002 SUPER DUTY F SERIES 2001-2002 EXPLORER SPORT TRAC ISSUE Some vehicles may exhibit a "Squeak" or Bind condition of the Tailgate. This may be caused by the grease on the tailgate hinges that may wash out prematurely causing a squeak or binding condition. ACTION Verify condition. Apply Silicone grease to correct the condition. Refer the the following Service Procedure for details. SERVICE PROCEDURE 1. Remove tail gate from the vehicle. 2. Remove plastic inserts from tail gate hinge cups. 3. Clean inside of hinge cups. 4. Apply grease (use only XG-3), to all inside surfaces of right and left side hinge cups and right and left side body side pins (Figure 1) and re-install plastic inserts into tail gate. 5. Reinstall the tail gate Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Hinge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tailgate Hinge: > 02-3-5 > Feb > 02 > Tailgate - Squeaking/Binding Condition > Page 10264 Parts Block OTHER APPLICABLE ARTICLES: NONE OPERATION DESCRIPTION TIME 020305A Apply Grease As 0.3 Hr. Instructed In Service Procedure DEALER CODING CONDITION BASIC PART NO. CODE 99430B22 41 OASIS CODES: 111000,112600, 702000, 702200 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Specifications Tailgate Latch: Specifications Tailgate Latch Screws ......................................................................................................................... ............................................. 21-29 Nm (16-21 ft lbs) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair > Tailgate Latch Tailgate Latch: Service and Repair Tailgate Latch REMOVAL 1. Open the tailgate. 2. Remove the tailgate access panel. 1. Remove the screws. 2. Remove the tailgate access panel. 3. Disconnect the tailgate latch rod. 1. Open the clip. 2. Disconnect the rod. 4. Remove the tailgate latch (RH shown, LH similar). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair > Tailgate Latch > Page 10270 1. Remove the two screws. 2. Remove the tailgate latch. INSTALLATION 1. To install, reverse the removal procedure. 1. If necessary, use Multi-Purpose Grease Spray F5AZ-19G209-AA or equivalent meeting Ford specification ESR-M1C159-A to lubricate the latches. NOTE: Make sure the latch release rods are not preloading the latches. They should be clipped in a relaxed state with no slack. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair > Tailgate Latch > Page 10271 Tailgate Latch: Service and Repair Tailgate Latch Remote Control REMOVAL 1. Open the tailgate. 2. Remove the tailgate access panel. 1. Remove the screws. 2. Remove the tailgate access panel. 3. Disconnect the tailgate latch rods. 1. Open the two clips. 2. Disconnect the two rods. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Latch > Component Information > Service and Repair > Tailgate Latch > Page 10272 4. Remove the tailgate handle. 1. Remove the nuts. 2. Remove the tailgate handle. 3. Remove the tailgate latch remote control. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Make sure the latch release rods are not preloading the latches. They should be clipped in a relaxed state with no slack. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Tailgate > Tailgate Lock Cylinder > Component Information > Service and Repair Tailgate Lock Cylinder: Service and Repair REMOVAL NOTE: Individual lock cylinders are repaired by discarding the inoperative cylinder and building a new lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed instruction sheet to build the new lock cylinder to the correct key code of the vehicle. 1. Remove the tailgate handle. 2. Remove the tailgate lock cylinder. 1. Remove the spring clip. 2. Remove the tailgate lock cylinder. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Make sure the lock release rod is not preloading the latch. It should be clipped in a relaxed state with no slack. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Service and Repair Cowl: Service and Repair REMOVAL 1. Remove the windshield wiper pivot arms. 1 Remove the two covers. 2 Remove the two nuts. 3 Remove the windshield wiper pivot arms. 2. Raise and support the hood. 3. Remove the cowl grille seal. 4. Remove the LH cowl grille. 1 Remove the screw cover. 2 Remove the screws. 3 Remove the clips. 4 Remove the pin-type retainer. 5 Remove the LH cowl grille. NOTE: The two cowl grilles overlap at the center.The LH cowl grille must be removed first. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Service and Repair > Page 10280 5. Remove the RH cowl grille. 1 Remove the screw cover. 2 Remove the screws. 3 Remove the clips. 4 Remove the pin-type retainer. 5 Remove the RH cowl grille. INSTALLATION 1. To install, reverse the removal procedure. NOTE: Adjust the wiper arms. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises Technical Service Bulletin # 99-6-5 Date: 990405 Side Doors - Wind Noises Article No. 99-6-5 04/05/99 WINDNOISE - AROUND SIDE DOOR(S) - SERVICE TIPS FORD: 1994-99 CROWN VICTORIA, ESCORT, TAURUS 1995-99 CONTOUR LINCOLN-MERCURY: 1994-98 MARK VIII 1994-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1994-97 F-150-350 SERIES 1994-99 ECONOLINE, EXPLORER, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, F-250 LD, MOUNTAINEER 1998-99 F-150, NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to add model year coverage and specify a standard door weatherstrip service push pin. ISSUE Windnoise from the side doors may be heard on some vehicles. This may be caused by the door weatherstrip seal. This TSB article provides Service Tips for correcting this concern. ACTION Diagnose and repair any windnoise from door weatherstrip concerns using the following Windnoise Service Tips. PART NUMBER PART NAME E8AZ-19552-A Weatherstrip And Rubber Adhesive E8AZ-19554-A Instant Adhesive N806340-S Snap-On Push Pin OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-18-5 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 110000, 701000 Windnoise Service Tips DO NOT REPLACE THE WEATHERSTRIP UNLESS IT IS: ^ Torn ^ Ripped ^ Cut ^ Deteriorated excessively ^ Material defect/abnormalities, or ^ TSB specifies the replacement of the weatherstrip Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 10289 NOTE REPLACEMENT SHOULD BE DUE TO NORMAL USE, NOT DUE TO CUSTOMER MISUSE. Weatherstrip Windnoise or Appearance Service Tips The following text explains attachment methods for Ford Motor Company's generic repair standards for loose and/or misaligned weatherstrips. Flanges are typically used on the body opening where weatherstrip retention fins grab onto each side of the sheet metal flange to retain the weatherstrip with a press fit. In cases where these weatherstrips become loose and/or misaligned, they can be reinstalled by pressing the locking retention fins back onto the sheet metal flange and stretching to provide better retention around corners. If the weatherstrip retention fins or metal carrier become damaged, it is also required that the U-section be carefully bent back into the proper shape to properly lock onto the sheet metal flange. Once replaced, check the weatherstrip for proper retention. If required, Weatherstrip and Rubber Adhesive (E8AZ-19552-A or equivalent meeting Ford specification ESB-M2G14-A) should be applied to the inside of the weatherstrip U-section to bond with the sheet metal flange for proper retention force. Sheet Metal C-Channels are typically used on the upper perimeter of the door assembly or body panel to hold the weatherstrip molded base inside the C-channel. In cases where these weatherstrips pop out of the channel, repair by first removing the weatherstrip from the entire channel, and reassemble by sliding the molded base back into the channel. If the sheet metal channel has been damaged, it is also required that the C-channel be carefully bent back into the proper shape to retain the weatherstrip molded base. Push Pins are typically used on the lower perimeter of the door assembly attached to the weatherstrip. They are press fit into sheet metal holes for retention. Push pins can be gently removed by pulling the actual pin normal to the surface, out of the hole, and reinserted without damage. If a push pin is damaged, it should be replaced by first removing the existing push pin. Then, the base of a new push pin should be inserted into the weatherstrip hole, and finally press fit into the corresponding sheet metal hole. All door perimeter weatherstrip push pins should be repaired using Ford standard N806340-S. Rivets are used to attach some weatherstrips to the sheet metal body. In cases where a rivet becomes loose, the entire rivet should be removed and replaced with a new rivet. Adhesive Tape is used to adhere smaller weatherstrip sections to the painted sheet metal surface. All surfaces must be clean and dry before any weatherstrip reattachment is performed. Adhesive tears should be reattached to the painted surface using general purpose Instant Adhesive (E8AZ-19554-A or equivalent). Verification 1. If the weatherstrip is not attached properly, reattach it correctly. 2. If the condition of the weatherstrip is good and it is attached properly, test drive the vehicle to diagnose the root cause of the windnoise. Verify the sealing contact between the door and the weatherstrip is sufficient with the 3X5" Card Test or a Chalk Test found in this TSB article. 3. If sealing contact between the weatherstrip and the door is the root cause of the windnoise, readjust the doors to contact the weatherstrips. NOTE WEATHERSTRIP REPAIRS SHOULD NOT CREATE UNACCEPTABLE DOOR CLOSING EFFORTS, WINDNOISE CONCERNS, OR WATER LEAK CONCERNS WITH THE DOOR SYSTEM. 3X5" Card Test 1. Insert a 3x5" card between the door and the weatherstrip at the base of the A-pillar with the door closed. 2. Run the card up along the A-pillar. If the card easily moves at any location along the A-pillar, then the sealing contact between the door and the weatherstrip is insufficient and the door should be adjusted to increase the sealing contact. This test can only be used to evaluate the A-pillar sealing contact at the margin. To evaluate sealing contact of the primary and secondary weatherstrips, a Chalk Test must be performed. Chalk Test 1. Lightly and evenly spray the sheet metal sealing surface of the door and body with a tracing powder (chalk spray). 2. Gently close the door, applying pressure only at the latch to prevent overslam (which will give an inaccurate reading). 3. Open the door and inspect the seals for degree of compression and possible skips. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 10290 To provide adequate sealing contact, the weatherstrip-to-sheet metal contact should provide a tracing powder footprint width of 4-6 mm on the weatherstrips. Any skips or tracing powder footprints less than 3mm in width indicate insufficient door-to-weatherstrip sealing contact and the door should be adjusted to increase the sealing contact. Door Adjusting Refer to Figures 1 and 2. 1. The upper and lower door hinges provide sufficient in/out adjustment to increase door contact with the dynamic weatherstrips. The door should not be pried or forced into alignment. To properly correct the door fit to the weatherstrips, the door striker and/or hinge bolts to the door must be loosened and adjusted to perform the alignment procedure. Note that the door striker only controls the in/out location of the door at the rear latch area. The hinges control the in/out location of the door at the front, and the overall tip or tilt of the door when viewed from the front or rear. 2. Review the overall fit of the door to the surrounding panels, and the amount of compression of the weatherstrip at all locations around the door. The fitting procedure is mastered sequentially from the rear of the vehicle to the front: ^ from the quarter panel to the rear door ^ from the rear door to the front door Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 10291 ^ then the front door to the fender All mating surfaces should be reviewed and, if necessary, refit starting with correcting the rear door to the quarter panel and working forward. 3. The door should be adjusted to obtain proper seal compression while maintaining a good door fit. An adjustment may be required only at one hinge. For example: if the top of the door is outboard, causing a lack of seal compression around the upper door frame area, and the fit of the lower part of the door is good to the adjacent panels, an inward adjustment at only the upper hinge would be appropriate (refer to Step 5). Note that adjustments to the rear door may require additional adjustments to the front door, and then also possibly to the front fender to maintain the proper panel fit and alignment. 4. The rear of the door should be set in/out with the striker to align at the door latch area with the mating panel. If the upper or lower part of the door doesn't align to the adjacent panel, the amount of door tip must be corrected by adjustment at the hinges in order to get both the upper and lower surfaces of the door aligned or flushed to the adjacent panels. 5. The in/out setting at the front of the doors is controlled by the hinge adjustment. ^ It should be set to obtain the proper amount of seal contact, which can be determined using the 3X5" Card Test or the Chalk Test. ^ As a guideline, if there is insufficient weatherstrip contact of the door, the hinge(s) should be adjusted 2-4 mm inboard. This is accomplished by loosening the hinge~to-door bolts just enough to permit movement of the door with a padded pry bar. ^ Only one hinge should be adjusted at a time. The other tight hinge helps to prevent any drastic door movement (which may result due to the weight of the door) which will result in a complete door refitting for both up/down as well as in/out positions. ^ The amount of movement can be determined by outlining the hinge mounting area on the door prior to adjustment, and measuring the hinge movement relative to this outline after adjustment. A 2-4mm adjustment should be sufficient to return the door to within its nominal operating range. 6. Finally, the door closing effort should be checked to be sure the seal compression has not increased so much that a closing effort concern has been created. If the efforts are unacceptably high, the door may have been moved excessively inward, and should be refitted outward to a location that balances the seal compression for windnoise with closing efforts. It may be necessary to perform another 3X5" Card Test or Chalk Test to verify the final seal compression. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises Technical Service Bulletin # 99-6-5 Date: 990405 Side Doors - Wind Noises Article No. 99-6-5 04/05/99 WINDNOISE - AROUND SIDE DOOR(S) - SERVICE TIPS FORD: 1994-99 CROWN VICTORIA, ESCORT, TAURUS 1995-99 CONTOUR LINCOLN-MERCURY: 1994-98 MARK VIII 1994-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1995-99 MYSTIQUE LIGHT TRUCK: 1994-97 F-150-350 SERIES 1994-99 ECONOLINE, EXPLORER, RANGER 1995-99 WINDSTAR 1997-99 EXPEDITION, F-250 LD, MOUNTAINEER 1998-99 F-150, NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to add model year coverage and specify a standard door weatherstrip service push pin. ISSUE Windnoise from the side doors may be heard on some vehicles. This may be caused by the door weatherstrip seal. This TSB article provides Service Tips for correcting this concern. ACTION Diagnose and repair any windnoise from door weatherstrip concerns using the following Windnoise Service Tips. PART NUMBER PART NAME E8AZ-19552-A Weatherstrip And Rubber Adhesive E8AZ-19554-A Instant Adhesive N806340-S Snap-On Push Pin OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-18-5 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 110000, 701000 Windnoise Service Tips DO NOT REPLACE THE WEATHERSTRIP UNLESS IT IS: ^ Torn ^ Ripped ^ Cut ^ Deteriorated excessively ^ Material defect/abnormalities, or ^ TSB specifies the replacement of the weatherstrip Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 10297 NOTE REPLACEMENT SHOULD BE DUE TO NORMAL USE, NOT DUE TO CUSTOMER MISUSE. Weatherstrip Windnoise or Appearance Service Tips The following text explains attachment methods for Ford Motor Company's generic repair standards for loose and/or misaligned weatherstrips. Flanges are typically used on the body opening where weatherstrip retention fins grab onto each side of the sheet metal flange to retain the weatherstrip with a press fit. In cases where these weatherstrips become loose and/or misaligned, they can be reinstalled by pressing the locking retention fins back onto the sheet metal flange and stretching to provide better retention around corners. If the weatherstrip retention fins or metal carrier become damaged, it is also required that the U-section be carefully bent back into the proper shape to properly lock onto the sheet metal flange. Once replaced, check the weatherstrip for proper retention. If required, Weatherstrip and Rubber Adhesive (E8AZ-19552-A or equivalent meeting Ford specification ESB-M2G14-A) should be applied to the inside of the weatherstrip U-section to bond with the sheet metal flange for proper retention force. Sheet Metal C-Channels are typically used on the upper perimeter of the door assembly or body panel to hold the weatherstrip molded base inside the C-channel. In cases where these weatherstrips pop out of the channel, repair by first removing the weatherstrip from the entire channel, and reassemble by sliding the molded base back into the channel. If the sheet metal channel has been damaged, it is also required that the C-channel be carefully bent back into the proper shape to retain the weatherstrip molded base. Push Pins are typically used on the lower perimeter of the door assembly attached to the weatherstrip. They are press fit into sheet metal holes for retention. Push pins can be gently removed by pulling the actual pin normal to the surface, out of the hole, and reinserted without damage. If a push pin is damaged, it should be replaced by first removing the existing push pin. Then, the base of a new push pin should be inserted into the weatherstrip hole, and finally press fit into the corresponding sheet metal hole. All door perimeter weatherstrip push pins should be repaired using Ford standard N806340-S. Rivets are used to attach some weatherstrips to the sheet metal body. In cases where a rivet becomes loose, the entire rivet should be removed and replaced with a new rivet. Adhesive Tape is used to adhere smaller weatherstrip sections to the painted sheet metal surface. All surfaces must be clean and dry before any weatherstrip reattachment is performed. Adhesive tears should be reattached to the painted surface using general purpose Instant Adhesive (E8AZ-19554-A or equivalent). Verification 1. If the weatherstrip is not attached properly, reattach it correctly. 2. If the condition of the weatherstrip is good and it is attached properly, test drive the vehicle to diagnose the root cause of the windnoise. Verify the sealing contact between the door and the weatherstrip is sufficient with the 3X5" Card Test or a Chalk Test found in this TSB article. 3. If sealing contact between the weatherstrip and the door is the root cause of the windnoise, readjust the doors to contact the weatherstrips. NOTE WEATHERSTRIP REPAIRS SHOULD NOT CREATE UNACCEPTABLE DOOR CLOSING EFFORTS, WINDNOISE CONCERNS, OR WATER LEAK CONCERNS WITH THE DOOR SYSTEM. 3X5" Card Test 1. Insert a 3x5" card between the door and the weatherstrip at the base of the A-pillar with the door closed. 2. Run the card up along the A-pillar. If the card easily moves at any location along the A-pillar, then the sealing contact between the door and the weatherstrip is insufficient and the door should be adjusted to increase the sealing contact. This test can only be used to evaluate the A-pillar sealing contact at the margin. To evaluate sealing contact of the primary and secondary weatherstrips, a Chalk Test must be performed. Chalk Test 1. Lightly and evenly spray the sheet metal sealing surface of the door and body with a tracing powder (chalk spray). 2. Gently close the door, applying pressure only at the latch to prevent overslam (which will give an inaccurate reading). 3. Open the door and inspect the seals for degree of compression and possible skips. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 10298 To provide adequate sealing contact, the weatherstrip-to-sheet metal contact should provide a tracing powder footprint width of 4-6 mm on the weatherstrips. Any skips or tracing powder footprints less than 3mm in width indicate insufficient door-to-weatherstrip sealing contact and the door should be adjusted to increase the sealing contact. Door Adjusting Refer to Figures 1 and 2. 1. The upper and lower door hinges provide sufficient in/out adjustment to increase door contact with the dynamic weatherstrips. The door should not be pried or forced into alignment. To properly correct the door fit to the weatherstrips, the door striker and/or hinge bolts to the door must be loosened and adjusted to perform the alignment procedure. Note that the door striker only controls the in/out location of the door at the rear latch area. The hinges control the in/out location of the door at the front, and the overall tip or tilt of the door when viewed from the front or rear. 2. Review the overall fit of the door to the surrounding panels, and the amount of compression of the weatherstrip at all locations around the door. The fitting procedure is mastered sequentially from the rear of the vehicle to the front: ^ from the quarter panel to the rear door ^ from the rear door to the front door Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 99-6-5 > Apr > 99 > Side Doors - Wind Noises > Page 10299 ^ then the front door to the fender All mating surfaces should be reviewed and, if necessary, refit starting with correcting the rear door to the quarter panel and working forward. 3. The door should be adjusted to obtain proper seal compression while maintaining a good door fit. An adjustment may be required only at one hinge. For example: if the top of the door is outboard, causing a lack of seal compression around the upper door frame area, and the fit of the lower part of the door is good to the adjacent panels, an inward adjustment at only the upper hinge would be appropriate (refer to Step 5). Note that adjustments to the rear door may require additional adjustments to the front door, and then also possibly to the front fender to maintain the proper panel fit and alignment. 4. The rear of the door should be set in/out with the striker to align at the door latch area with the mating panel. If the upper or lower part of the door doesn't align to the adjacent panel, the amount of door tip must be corrected by adjustment at the hinges in order to get both the upper and lower surfaces of the door aligned or flushed to the adjacent panels. 5. The in/out setting at the front of the doors is controlled by the hinge adjustment. ^ It should be set to obtain the proper amount of seal contact, which can be determined using the 3X5" Card Test or the Chalk Test. ^ As a guideline, if there is insufficient weatherstrip contact of the door, the hinge(s) should be adjusted 2-4 mm inboard. This is accomplished by loosening the hinge~to-door bolts just enough to permit movement of the door with a padded pry bar. ^ Only one hinge should be adjusted at a time. The other tight hinge helps to prevent any drastic door movement (which may result due to the weight of the door) which will result in a complete door refitting for both up/down as well as in/out positions. ^ The amount of movement can be determined by outlining the hinge mounting area on the door prior to adjustment, and measuring the hinge movement relative to this outline after adjustment. A 2-4mm adjustment should be sufficient to return the door to within its nominal operating range. 6. Finally, the door closing effort should be checked to be sure the seal compression has not increased so much that a closing effort concern has been created. If the efforts are unacceptably high, the door may have been moved excessively inward, and should be refitted outward to a location that balances the seal compression for windnoise with closing efforts. It may be necessary to perform another 3X5" Card Test or Chalk Test to verify the final seal compression. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10309 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10310 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10311 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10312 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10313 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10314 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10315 Attachment III - Technical Information Table of Contents Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10316 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10317 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10318 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10319 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10320 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10321 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10322 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10323 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10324 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10325 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10326 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10327 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10328 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10329 ERROR: stackunderflow OFFENDING COMMAND: begin STACK: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls: > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): Recalls Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls: > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 10334 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls: > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Brake Switch (Cruise Control): Recalls Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-19-2 > Oct > 01 > Rear Brakes - Grabbing On First Few Applications Brake Shoe: All Technical Service Bulletins Rear Brakes - Grabbing On First Few Applications Article No. 01-19-2 10/01/01 BRAKES - REAR DRUM - GRABBING DURING FIRST FEW BRAKE APPLICATIONS WHILE BRAKES ARE COLD FORD: 1997-2000 F-150 This article is being republished in its entirety to update the Model Year coverage. ISSUE A grabbing condition from the rear brakes during the first few brake applications after extended humidity exposure may occur on some vehicles. This may be caused by a rear brake lining that is sensitive to humidity exposure. ACTION Replace rear brake linings with revised Rear Shoe Brake Kit (F85Z-2200-AA). Refer to the appropriate model year F-150 Workshop Manual, Section 206-02 for service details. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-10-7 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011902A Replace Rear Brake Shoes 1.2 Hrs. DEALER CODING CONDITION BASIC PART NO. CODE 2200 49 OASIS CODES: 301000, 702200 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 01-19-2 > Oct > 01 > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 01-19-2 > Oct > 01 > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10353 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 01-19-2 > Oct > 01 > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10354 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 01-19-2 > Oct > 01 > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10355 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 01-19-2 > Oct > 01 > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10356 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 01-19-2 > Oct > 01 > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10357 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 01-19-2 > Oct > 01 > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10358 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 01-19-2 > Oct > 01 > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10359 Attachment III - Technical Information Table of Contents Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 01-19-2 > Oct > 01 > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10360 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 01-19-2 > Oct > 01 > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10361 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 01-19-2 > Oct > 01 > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10362 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 01-19-2 > Oct > 01 > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10363 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 01-19-2 > Oct > 01 > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10364 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 01-19-2 > Oct > 01 > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10365 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 01-19-2 > Oct > 01 > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10366 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 01-19-2 > Oct > 01 > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10367 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 01-19-2 > Oct > 01 > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10368 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 01-19-2 > Oct > 01 > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10369 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 01-19-2 > Oct > 01 > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10370 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 01-19-2 > Oct > 01 > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10371 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 01-19-2 > Oct > 01 > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10372 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 01-19-2 > Oct > 01 > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10373 ERROR: stackunderflow OFFENDING COMMAND: begin STACK: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 01-19-2 > Oct > 01 > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): Recalls Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 01-19-2 > Oct > 01 > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 10378 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Switch (Cruise Control): > 01-19-2 > Oct > 01 > Recalls for Brake Switch (Cruise Control): > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Brake Switch (Cruise Control): Recalls Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10388 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10389 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10390 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10391 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10392 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10393 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10394 Attachment III - Technical Information Table of Contents Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10395 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10396 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10397 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10398 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10399 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10400 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10401 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10402 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10403 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10404 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10405 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10406 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10407 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10408 ERROR: stackunderflow OFFENDING COMMAND: begin STACK: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > NHTSA07V336000 > Aug > 07 > All Technical Service Bulletins for Brake Shoe: > 01-19-2 > Oct > 01 > Rear Brakes - Grabbing On First Few Applications Brake Shoe: All Technical Service Bulletins Rear Brakes - Grabbing On First Few Applications Article No. 01-19-2 10/01/01 BRAKES - REAR DRUM - GRABBING DURING FIRST FEW BRAKE APPLICATIONS WHILE BRAKES ARE COLD FORD: 1997-2000 F-150 This article is being republished in its entirety to update the Model Year coverage. ISSUE A grabbing condition from the rear brakes during the first few brake applications after extended humidity exposure may occur on some vehicles. This may be caused by a rear brake lining that is sensitive to humidity exposure. ACTION Replace rear brake linings with revised Rear Shoe Brake Kit (F85Z-2200-AA). Refer to the appropriate model year F-150 Workshop Manual, Section 206-02 for service details. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-10-7 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011902A Replace Rear Brake Shoes 1.2 Hrs. DEALER CODING CONDITION BASIC PART NO. CODE 2200 49 OASIS CODES: 301000, 702200 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > NHTSA05V388000 > Sep > 05 > Component Information > Technical Service Bulletins > Customer Interest for Brake Shoe: > 01-19-2 > Oct > 01 > Rear Brakes - Grabbing On First Few Applications Brake Shoe: Customer Interest Rear Brakes - Grabbing On First Few Applications Article No. 01-19-2 10/01/01 BRAKES - REAR DRUM - GRABBING DURING FIRST FEW BRAKE APPLICATIONS WHILE BRAKES ARE COLD FORD: 1997-2000 F-150 This article is being republished in its entirety to update the Model Year coverage. ISSUE A grabbing condition from the rear brakes during the first few brake applications after extended humidity exposure may occur on some vehicles. This may be caused by a rear brake lining that is sensitive to humidity exposure. ACTION Replace rear brake linings with revised Rear Shoe Brake Kit (F85Z-2200-AA). Refer to the appropriate model year F-150 Workshop Manual, Section 206-02 for service details. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-10-7 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011902A Replace Rear Brake Shoes 1.2 Hrs. DEALER CODING CONDITION BASIC PART NO. CODE 2200 49 OASIS CODES: 301000, 702200 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > NHTSA05V388000 > Sep > 05 > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Shoe: > 01-19-2 > Oct > 01 > Rear Brakes - Grabbing On First Few Applications Brake Shoe: All Technical Service Bulletins Rear Brakes - Grabbing On First Few Applications Article No. 01-19-2 10/01/01 BRAKES - REAR DRUM - GRABBING DURING FIRST FEW BRAKE APPLICATIONS WHILE BRAKES ARE COLD FORD: 1997-2000 F-150 This article is being republished in its entirety to update the Model Year coverage. ISSUE A grabbing condition from the rear brakes during the first few brake applications after extended humidity exposure may occur on some vehicles. This may be caused by a rear brake lining that is sensitive to humidity exposure. ACTION Replace rear brake linings with revised Rear Shoe Brake Kit (F85Z-2200-AA). Refer to the appropriate model year F-150 Workshop Manual, Section 206-02 for service details. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 99-10-7 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 011902A Replace Rear Brake Shoes 1.2 Hrs. DEALER CODING CONDITION BASIC PART NO. CODE 2200 49 OASIS CODES: 301000, 702200 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > NHTSA05V388000 > Sep > 05 > Component Information > Technical Service Bulletins > Page 10432 Brake Shoe: Specifications Lining Minimum Thickness Standard 1/32 in Heavy Duty 1/32 in Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > NHTSA05V388000 > Sep > 05 > Component Information > Adjustments > Drums Installed Brake Shoe: Adjustments Drums Installed 1. Raise and support the vehicle. 2. At the back of the brake backing plate, remove the brake adjusting hole cover. 3. Rotate the brake shoe adjusting screw nut. 1 Using a screwdriver, move the brake shoe adjusting lever off the brake shoe adjusting screw nut. 2 NOTE: Move the adjustment tool handle upward to tighten the brake adjuster screw. Turn the brake shoe adjusting screw nut until the brake drum begins to drag. Then loosen the brake adjuster screw until the brake drum rotates freely. 4. Replace the brake adjusting hole cover. 5. Lower the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > NHTSA05V388000 > Sep > 05 > Component Information > Adjustments > Drums Installed > Page 10435 Brake Shoe: Adjustments Drums Removed WARNING: Asbestos fiber dust can be present on brake and clutch assemblies and is hazardous to health if inhaled. Brake and clutch assemblies must be cleaned using a vacuum cleaner recommended for use with asbestos fibers, such as a brake/clutch/service vacuum. The bag must be labeled per OSHA instructions, sealed, and the trash hauler notified as to the bag's contents. If a vacuum suitable for asbestos is not available, cleaning must be done wet. If dust generation is still possible, technicians must wear government-approved toxic dust purifying respirators. The occupational safety and health act (OSHA) requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians performing brake or clutch repair are to be present in the area. NOTE: After adjusting the rear brake shoes and linings, check the parking brake for proper operation. Make sure the parking brake cable equalizer operates freely. 1. Measure the brake drum inside diameter. - Use a brake adjustment gauge. 2. Adjust the rear brake shoes and linings. - Rotate the brake adjuster screw until the rear brake shoes and linings touch the tool. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > NHTSA05V388000 > Sep > 05 > Component Information > Service and Repair > Heavy-Duty Brake Shoe: Service and Repair Heavy-Duty Special Tools Removal WARNING: Asbestos fiber dust can be present on brake and clutch assemblies and is hazardous to health if inhaled. Brake and clutch assemblies must be cleaned using a vacuum cleaner recommended for use with asbestos fibers, such as the brake/clutch/service vacuum. The bag must be labeled per OSHA instructions, sealed, and the trash hauler notified as to the bag's contents. If a vacuum suitable for asbestos is not available, cleaning must be done wet. If dust generation is still possible, technicians must wear government-approved toxic dust purifying respirators. The occupational safety and health act (OSHA) requires areas where asbestos dust generation is possible to be isolated and posted with warning signs. Only technicians performing brake or clutch repair are to be present in the area. WARNING: To reduce the possibility of uneven braking, always replace rear brake shoes and linings at both ends of an axle. 1. Remove the brake drum. 2. Inspect the rear brake assembly for the following: - the rear wheel cylinder for excessive leakage that can contaminate brake system parts, and rebuild as necessary. - the rear brake shoes and linings for contamination, and replace as necessary. - the rear brake shoes and linings for minimum thickness above backing plate or rivets, and replace as necessary. - the springs for heat discoloration, and replace as necessary. 3. Remove the brake shoe retracting spring. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > NHTSA05V388000 > Sep > 05 > Component Information > Service and Repair > Heavy-Duty > Page 10438 4. Disconnect the parking brake lever. 1 Remove the parking brake lever bolt lock nut, at the back of the brake backing plate, and the parking brake lever bolt. 2 Remove the parking brake rear cable and conduit from the parking brake lever. 5. Remove the parking brake lever. 6. Remove the adjusting screw assembly. 1 Disconnect the brake shoe adjusting lever cable from the brake shoe adjusting lever. 2 Remove the brake shoe adjusting lever cable. 3 Remove the cable guide, 4 Remove the adjusting lever return spring and the brake shoe adjusting lever. 5 Remove the brake shoe adjusting screw spring. 6 Remove the brake adjuster screw assembly. 7. Remove the rear brake shoe and lining. 1 Remove the brake shoe anchor pin guide plate. 2 Remove the brake shoe hold-down springs and the brake shoe hold-down spring pins. 3 Remove the rear brake shoes and linings. Installation Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > NHTSA05V388000 > Sep > 05 > Component Information > Service and Repair > Heavy-Duty > Page 10439 1. Lubricate the brake backing plate friction points. Use Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft WA-10) or an equivalent silicone compound meeting Ford specification ESE-M1C171-A. 2. Install the rear brake shoes and linings. 1 Position the rear brake shoes and linings. 2 Install the brake shoe hold-down spring pins and the brake shoe hold-down springs. 3 Install the brake shoe anchor pin guide plate. 3. NOTE: To prevent incorrect installation, the socket end of each brake adjuster screw is stamped R or L. Assemble the brake adjuster screw assembly. 1 Apply Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft WA-10) or an equivalent silicone compound meeting Ford specification ESE-M1C171-A. 2 Install the brake adjuster screw into the brake shoe adjusting screw nut to the end of the threads, and then loosen one-half turn. 3 Install the brake shoe adjusting screw socket on the brake shoe adjusting screw nut. 4. Install the brake adjuster screw assembly. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > NHTSA05V388000 > Sep > 05 > Component Information > Service and Repair > Heavy-Duty > Page 10440 1 Position the brake adjuster screw assembly. 2 Install the brake shoe adjusting screw spring. 3 Position the brake shoe adjusting lever cable. 4 Install the cable guide. 5 Position the adjusting lever return spring and the brake shoe adjusting lever. 6 Hook the brake shoe adjusting lever cable to the brake shoe adjusting lever. 5. Test the operation of the automatic self-adjuster. 1 Pull the brake shoe adjusting lever cable and check that the brake shoe adjusting lever rotates the brake shoe adjuster assembly. 2 Release the brake shoe adjusting lever cable and check that the brake shoe adjusting lever advances to the next notch on the brake shoe adjusting screw nut. 6. Install the parking brake lever. 1 Attach the parking brake rear cable and conduit to the parking brake lever. 2 Position the parking brake lever. 3 Install the parking brake lever bolt and, at the back of the brake backing plate, the parking brake lever bolt lock nut. 7. Install the brake shoe retracting spring. 8. Adjust the brakes. 9. Install the brake drum. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > NHTSA05V388000 > Sep > 05 > Component Information > Service and Repair > Heavy-Duty > Page 10441 Brake Shoe: Service and Repair Standard Special Tools Removal 1. Remove the brake drum. 2. Inspect the rear brake assembly for the following: - the rear wheel cylinder for excessive leakage that can contaminate brake system parts, and rebuild as necessary. - the rear brake shoes and linings for contamination, and replace as necessary. - the rear brake shoes and linings for minimum thickness, above the backing plate or rivets, and replace as necessary. - the springs for heat discoloration, and replace as necessary. - the adjusting lever contact with the brake adjuster screw. 3. NOTE: To aid installation, note the locations of the short and long brake shoe retracting springs. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > NHTSA05V388000 > Sep > 05 > Component Information > Service and Repair > Heavy-Duty > Page 10442 Remove the brake shoe retracting springs. 1 Remove the long brake shoe retracting spring. 2 Remove the short brake shoe retracting spring. 4. Remove the adjusting screw assembly. 1 Disconnect the brake shoe adjusting lever cable from the brake shoe adjusting lever. 2 Remove the brake shoe adjusting lever cable. 3 Remove the cable guide. 4 Remove the adjusting lever return spring and the brake shoe adjusting lever. 5 Remove the brake shoe adjusting screw spring. 6 Remove the brake adjuster screw assembly. 5. NOTE: The parking brake link spring and the brake parking spring retainer will come off with the parking brake strut. Remove the brake shoe anchor pin guide plate, parking brake strut and the parking brake lever pin retainer. 6. Remove the rear brake shoes and linings. 1 Remove the brake shoe hold-down springs. 2 Remove the rear brake shoes and linings. 3 Remove the brake shoe hold-down spring pins. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > NHTSA05V388000 > Sep > 05 > Component Information > Service and Repair > Heavy-Duty > Page 10443 7. Pull back the parking brake cable spring and disconnect the parking brake lever. Installation 1. Compress the parking brake cable spring and attach the parking brake lever. 2. Clean and lubricate the brake backing plate. - Use Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft WA-10) or an equivalent silicone compound meeting Ford specification ESE-M1C171-A. 3. Attach the parking brake lever to the rear brake shoe and lining and secure the parking brake lever pin retainer. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > NHTSA05V388000 > Sep > 05 > Component Information > Service and Repair > Heavy-Duty > Page 10444 4. Install the rear brake shoes and linings. 1 Position the rear brake shoes and linings. 2 Install the brake shoe hold-down spring pins and the brake shoe hold-down springs. 5. Install the parking brake strut. 1 Install the parking brake link spring and the parking brake spring retainer on the parking brake strut. 2 Install the parking brake strut. 3 Install the brake shoe anchor pin guide plate. 6. Install the short brake shoe retracting spring. 1 Place the brake shoe adjusting lever cable over the anchor pin, with crimped side in. 2 Install the short brake shoe retracting spring. 7. NOTE: Make sure the brake shoe adjusting lever cable is positioned in the cable guide groove. Install the long brake shoe retracting spring. 1 Install the cable guide. 2 Position the brake shoe adjusting lever cable in the cable guide groove. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > NHTSA05V388000 > Sep > 05 > Component Information > Service and Repair > Heavy-Duty > Page 10445 3 Install the long brake shoe retracting spring. 8. NOTE: To prevent incorrect installation, the socket end of each brake adjuster screw is stamped R or L. Assemble the brake adjuster screw assembly. 1 Apply Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft WA-10) or an equivalent silicone compound meeting Ford specification ESE-M1C171-A. 2 Install the brake adjuster screw into the brake shoe adjusting screw nut to the end of the threads, and then loosen one-half turn. 3 Install the brake shoe adjusting screw socket on the brake shoe adjusting screw nut. 9. Install the brake adjuster screw assembly. 1 Position the brake adjuster screw assembly. 2 Install the brake shoe adjusting screw spring. 3 Position the brake shoe adjusting lever cable. 4 Position the adjusting lever return spring and the brake shoe adjusting lever. 5 Hook the brake shoe adjusting lever cable to the brake shoe adjusting lever. 10. Test the operation of the automatic self-adjuster. 1 Pull the brake shoe adjusting lever cable and check that the brake shoe adjusting lever rotates the brake shoe adjuster assembly. 2 Release the brake shoe adjusting lever cable and check that the brake shoe adjusting lever advances to the next notch on the brake shoe adjusting screw nut. 11. Adjust the brakes. 12. Install the brake drum. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Shoe: > NHTSA05V388000 > Sep > 05 > Component Information > Service and Repair > Page 10446 Brake Shoe: Tools and Equipment Special Tool Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications Front Front Axle Fluid Capacity Capacity ............................................................................................................................................... ............................................................ 3.5 - 3.7 Pints 3/8 inch below the bottom of fill hole. Rear Differential Fluid Capacity Capacity ............................................................................................................................................... .................................................................. 2.6 - 2.7L Fill no higher than 1/4 to 9/16 inch below fill plug. For complete fill of 8.8 and 9.75 Traction-Lok axles add 4 oz. of friction modifier C8AZ-19B956-A. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Component Information > Specifications > Capacity Specifications > Page 10450 Fluid - Differential: Fluid Type Specifications Front Axle ............................................................................................................................................ ............................................................. SAE 75W-90 Rear Axle ............................................................................................................................................. .......................................... SAE 75W-140 Synthetic Note: The rear axle is filled with a synthetic axle lubricant and is considered lubricated for life. These lubricants do not need to be checked nor changed unless a leak is suspected, service is required, or the axle has been submerged in water. The axle lubricant should be changed any time the axle has been submerged in water. Add 4 ounces of friction modifier additive C8AZ-19B546-A, Ford specification EST-M2C118A for complete refill of Traction-Lok axles. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Component Information > Specifications > Page 10451 Fluid - Differential: Service Precautions DO NOT over fill differential beyond normal fluid level. Fluid foaming and damage may occur. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Component Information > Page 10452 Fluid - Differential: Service Precautions DO NOT over fill differential beyond normal fluid level. Fluid foaming and damage may occur. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications Cruise Control Servo: Specifications Speed Control Servo Bracket to Vehicle Bolts ......................................................................................................................... 7.6-10.4 N.m (5.6-7.7 Lb-Ft) Speed Control Servo to Bracket Screws ........................................................................................................................................ 10-13 N.m (90-115 Lb-In) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 10456 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 10457 Cruise Control Servo: Service and Repair REMOVAL 1. Remove the speed control actuator cable cap from the speed control servo. 1 Push in the locking arm on the speed control actuator cable cap. 2 Rotate the speed control actuator cable cap counterclockwise and remove the speed control actuator cable cap from the speed control servo. 2. Disconnect the speed control actuator cable from the speed control servo. 1 Depress the spring retainer. 2 Slide the core wire end out of the speed control servo pulley. 3. Disconnect the speed control servo electrical connector. 4. Remove the speed control servo and bracket. 1 Remove the bolts. 2 Remove the speed control servo and bracket. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 10458 NOTE: Do not remove the rubber grommets from the speed control servo bracket. 5. Remove the speed control servo bracket. 1 Remove the screws. 2 Remove the speed control servo bracket. INSTALLATION 1. To install, reverse the removal procedure. NOTE: The rubber grommets must be properly seated in the speed control servo bracket for proper noise and vibration isolation. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Servo Cable: > NHTSA98V192000 > Aug > 98 > Recall 98V192000: Speed Control Cable Loose Cruise Control Servo Cable: All Technical Service Bulletins Recall 98V192000: Speed Control Cable Loose Vehicle Description: Light duty pickup trucks. A speed control cable may not have fully seated into the accelerator bracket at time of installation. If the cable is not fully seated into this bracket, the cable could separate from the bracket. A loose cable can result in the throttle not fully returning to idle and cause an increase in stopping distance. Dealers will add a retaining clip to the speed control cable fitting at the accelerator bracket. Ford is notifying dealers on or about August 11, 1998. These vehicles have not yet been released for sale to the public. 1999 FORD TRUCK F150 1999 FORD TRUCK F250 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > Recalls for Cruise Control Servo Cable: > NHTSA98V192000 > Aug > 98 > Recall 98V192000: Speed Control Cable Loose Cruise Control Servo Cable: Recalls Recall 98V192000: Speed Control Cable Loose Vehicle Description: Light duty pickup trucks. A speed control cable may not have fully seated into the accelerator bracket at time of installation. If the cable is not fully seated into this bracket, the cable could separate from the bracket. A loose cable can result in the throttle not fully returning to idle and cause an increase in stopping distance. Dealers will add a retaining clip to the speed control cable fitting at the accelerator bracket. Ford is notifying dealers on or about August 11, 1998. These vehicles have not yet been released for sale to the public. 1999 FORD TRUCK F150 1999 FORD TRUCK F250 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > Page 10472 Cruise Control Servo Cable: Service and Repair REMOVAL NOTE: 5.4L 2 Valve Triton V8 shown; others are similar. 1. Remove the accelerator control splash shield. 1 Remove the screws. 2 Remove the accelerator control splash shield. 2. Remove the speed control actuator cable from the throttle nail head. 1 Lift the speed control actuator cable upward. 2 Squeeze the speed control actuator cable tabs and remove from the throttle nail head. 3. Remove the speed control actuator cable cap from the speed control servo. 1 Push in the locking arm on the speed control actuator cable cap. 2 Rotate the speed control actuator cable cap counterclockwise and remove the speed control actuator cable cap from the speed control servo. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service Bulletins > Page 10473 4. Remove the speed control actuator cable. 1 Depress the spring retainer. 2 Slide the core wire end out of the speed control servo pulley and remove the speed control actuator cable. INSTALLATION 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Recalls: > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Cruise Control Switch: Recalls Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Cruise Control Switch: All Technical Service Bulletins Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cruise Control Switch: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference Oil Pressure Sender: All Technical Service Bulletins Oil Pressure Sending Unit - Drip Shield Interference Article No. 01-4-2 3/05/01 ENGINE - 5.4L - OIL SENDING UNIT INTERFERENCE FIT AT ENGINE OIL DRIP SHIELD - 4X4 VEHICLES EQUIPPED WITH 5.4L ENGINE ONLY FORD: 1998 F-250 LD 1998-2001 EXPEDITION, F-150 1999-2001 SUPER DUTY F SERIES LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit the engine oil sending unit contacting the oil drip shield attached to the front axle. This may be caused by tight tolerances between the engine oil sending unit and the engine oil drip shield. This may cause a malfunction of the engine oil sending unit. ACTION If the engine oil sending unit needs to be replaced due to contact with the drip shield, modify the engine oil drip shield as shown. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE IF THE ENGINE OIL SENDING UNIT NEEDS TO BE REPLACED IN SERVICE, MODIFY THE ENGINE OIL DRIP SHIELD BEFORE INSTALLING THE NEW ENGINE OIL SENDING UNIT. 1. Remove oil drip shield from front axle. This shield is attached to the front axle by three (3) bolts. 2. Modify shield as shown (Figure 1). Remove excess material from shield. Remove any sharp edges or burrs upon finishing cutting operation. 3. Reinstall engine oil drip shield. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cruise Control Switch: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference > Page 10492 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODE OASIS CODES: 401000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Cruise Control Switch: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference > Page 10498 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODE OASIS CODES: 401000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 10499 Cruise Control Switch: Service and Repair REMOVAL 1. Remove the driver side air bag module. 2. Remove the speed control actuator switch. 1 Release the four (A) speed control actuator switch clips and remove the (B) speed control actuator switch. 2 Disconnect the speed control actuator switch electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10509 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10510 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10511 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10512 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10513 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10514 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10515 Attachment III - Technical Information Table of Contents Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10516 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10517 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10518 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10519 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10520 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10521 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10522 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10523 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10524 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10525 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10526 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10527 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10528 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10529 ERROR: stackunderflow OFFENDING COMMAND: begin STACK: Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): Recalls Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 10534 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Brake Switch (Cruise Control): Recalls Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection Technical Service Bulletin # 05S28S15 Date: 080410 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10544 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10545 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10546 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10547 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10548 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10549 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10550 Attachment III - Technical Information Table of Contents Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10551 SCDS Identification The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is illustrated below. See Figure 1. Note that the revised SCDS has a different electrical connector. A jumper adapter (which is included in the parts kit) is required when replacing the old SCDS with the revised SCDS. SCDS Location In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder. In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just follow the metal brake lines from the master cylinder until the switch is found. ^ On early model year E-Series vehicles, the SCDS is located on the left frame rail. ^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to allow access to the SCDS and servo. ^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to reposition wiring harnesses and/or remove add-on equipment in order to locate the switch. ^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain access to the SCDS. - When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK position to prevent damage to the clockspring. - During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts to 49 Nm (36 lb-ft). ^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash shield in front of the right front wheel. It is not necessary to remove the right front wheel to access the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside. ^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left front fender splash shield in front of the left front wheel. FUSED JUMPER HARNESS (FJH) IDENTIFICATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10552 The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10553 PARTS APPLICATION CHART SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION NOTE: On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10554 Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake fluid. ^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a Fused Jumper Harness. - On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector, replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the speed control servo connector. ^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation Switch, inspect and apply electrical grease to the appropriate connectors. FUSED JUMPER HARNESS (FJH) INSTALLATION 1. Connect the fused jumper harness to the SCDS and the vehicle harness. 2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the top of the existing harness and verify proper fuse holder orientation. See Figure 4. SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT NOTE: The brake pedal must not be depressed during the removal and replacement of the SCDS. 1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level. NOTICE: DO NOT apply fluid to the electrical connector or damage to the connector may occur. NOTICE: The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the SCDS before installing it on the vehicle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10555 2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See Figure 5. NOTICE: Do not allow any foreign material to enter the master cylinder port once the SCDS is removed. NOTE: Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS fitting when the SCDS is removed. NOTE: If the new SCDS is not installed immediately after the original switch is removed, the master cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to bleed the brake system will not be covered under this program. 3. Remove the SCDS. 4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS. 5. Tighten the new SCDS as follows: ^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri. ^ 13 Nm (115 lb-in) - 1994 Capri. 6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake fluid reservoir cap. 7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage. See Figure 6. ^ If no heat damage is found at the speed control servo connector (even if there is presence of brake fluid in the connector), proceed to the next step. ^ If the speed control servo connector is heat damaged, call the Special Service Support Center for further instructions. 8. With the speed control servo disconnected, use shop air only to blow the SCDS harness electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of solvent to clean the connectors. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10556 9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip. 10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7. 11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness. Using the provided tie strap, secure the jumper harness to a nearby component such as the speed control cable or another wire harness. NOTICE: Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT apply the grease directly to the connector of the servo module. 12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire width and length of the servo vehicle harness connector. See Figure 8. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10557 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10558 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10559 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10560 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10561 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10562 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10563 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10564 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10565 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10566 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10567 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10568 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10569 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard Brake Switch (Cruise Control): All Technical Service Bulletins Recall 07V336000: Cruise Control Fire Hazard MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998 Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003 Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001 Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning 2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002 Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer 1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 07V336000 MFR'S REPORT DATE: August 02, 2007 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3600000 SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 10574 CONSEQUENCE: This could result in an underhood fire. REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected October 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed by September 19, 2007. Owners may contact Ford at 1-800-392-3673. NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Brake Switch (Cruise Control): All Technical Service Bulletins Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Page 10579 Brake Switch (Cruise Control): Specifications Deactivator Switch ............................................................................................................................... ........................................... 15-20 N.m (11-15 Lb-Ft) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service Bulletins > Page 10580 Brake Switch (Cruise Control): Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the deactivator switch electrical connector. 3. Remove the deactivator switch. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. - After the deactivator switch is installed, it is necessary to bleed the brake system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Recalls for Cruise Control Switch: > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Cruise Control Switch: Recalls Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Switch: > NHTSA05V388000 > Sep > 05 > Recall 05V388000: Cruise Control Switch Replacement Cruise Control Switch: All Technical Service Bulletins Recall 05V388000: Cruise Control Switch Replacement MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1994-1996 Ford/Expedition 1997-2002 Ford/F150 1994-2002 Ford/F250 1994-1999 Lincoln/Blackwood 2002 Lincoln/Navigator 1998-2002 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER: 05V388000 MFG'S REPORT DATE: September 07, 2005 COMPONENT: Vehicle Speed Control POTENTIAL NUMBER OF UNITS AFFECTED: 3800000 SUMMARY: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn. CONSEQUENCE: A fire at the switch could occur. REMEDY: As an interim repair, owners will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. As soon as replacement parts are available (expected mid-October 2005), owners will be instructed to return to the dealers for installation of a fused wiring harness. The interim owner notification is expected to begin during the week of September 12, 2005. Owners should contact Ford AT 1-800-392-3673. NOTES: Ford recall No. 05S28. Customers can also contact The National Highway Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to http://www.safercar.gov. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 10594 Cruise Control Switch: Service and Repair REMOVAL 1. Remove the driver side air bag module. 2. Remove the speed control actuator switch. 1 Release the four (A) speed control actuator switch clips and remove the (B) speed control actuator switch. 2 Disconnect the speed control actuator switch electrical connector. INSTALLATION 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > Customer Interest for Audible Warning Device: > 01-21-13 > Oct > 01 > Ignition Switch - High Turning Effort/MIL ON/DTC's Set Audible Warning Device: Customer Interest Ignition Switch - High Turning Effort/MIL ON/DTC's Set Article No. 01-21-13 10/29/01 ^ DRIVEABILITY - DIAGNOSTIC TROUBLE CODES (DTC) P0500, P1502 AND/OR U1039 CONTINENTAL MODELS ONLY - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN TURNING IGNITION SWITCH ^ ELECTRICAL - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN TURNING IGNITION SWITCH FORD: 1998-2002 CROWN VICTORIA, MUSTANG, TAURUS 1998-1999 F-250 LD 1998-2001 EXPLORER 1998-2002 E SERIES, EXPEDITION, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT 2001-2002 EXPLORER SPORT TRAC LINCOLN: 1998-2002 CONTINENTAL, TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 1998-2002 GRAND MARQUIS, SABLE 1998-2001 MOUNTAINEER ISSUE Some ignition switch lock cylinder assemblies may exhibit the following highly intermittent conditions: ^ Roughness and/or excessive effort in turning the key from RUN to START position. ^ Key does not fully return from START to RUN after starting vehicle. This may result in intermittent accessory function. ^ Continental ONLY - A malfunction indicator lamp may illuminate with diagnostic trouble codes P0500, P1502 and UlO3g stored in the Powertrain Control Modules (PCM) memory. This may be caused by a Key-In-Ignition warning chime switch. ACTION Replace the KEY-IN-IGNITION WARNING CHIME SWITCH located on the ignition switch lock cylinder with revised pant XL2Z-11A127-AB. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Disconnect the battery ground cable and wait at least one minute. 2. Insent the ignition key and turn it to the RUN position. 3. Insert a punch into the access hole (located in the lower steering column shroud, below the lock cylinder) and press the release button while pulling out the ignition switch lock cylinder. NOTE SOME VEHICLES DO NOT HAVE AN ACCESS HOLE AND REQUIRE LOWER SHROUD REMOVAL. REFER TO THE APPROPRIATE MODEL WORKSHOP MANUAL, IGNITION SWITCH LOCK CYLINDER REMOVAL AND INSTALLATION SECTION 211 IF ADDITIONAL DETAIL IS REQUIRED. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > Customer Interest for Audible Warning Device: > 01-21-13 > Oct > 01 > Ignition Switch - High Turning Effort/MIL ON/DTC's Set > Page 10604 4. Remove the Plastic Key chime warning switch by prying upward on the plastic retainer, while sliding the switch away from the key insertion end (Figure 1). Refer to the appropriate model Workshop Manual, Key-in-ignition warning switch removal and installation section located in Section 413 if additional detail is required. 5. Install a new Key-In-Ignition warning chime switch XL2Z-11A127-AB and reinstall lock cylinder. 6. Verify proper function of the Ignition Switch Lock Cylinder and Key-In-Ignition warning chime switch. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 012113A Replace The 0.3 Hr. Key-In-Ignition Warning Chime Switch DEALER CODING CONDITION BASIC PART NO. CODE 11A127 42 OASIS CODES: 102000, 112000, 202000, 203000, 204000, 204200, 205000, 206000, 207000, 208000, 208999, 301000, 302000, 497000, 504000, 601300, 603300, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Audible Warning Device: > 01-21-13 > Oct > 01 > Ignition Switch - High Turning Effort/MIL ON/DTC's Set Audible Warning Device: All Technical Service Bulletins Ignition Switch - High Turning Effort/MIL ON/DTC's Set Article No. 01-21-13 10/29/01 ^ DRIVEABILITY - DIAGNOSTIC TROUBLE CODES (DTC) P0500, P1502 AND/OR U1039 CONTINENTAL MODELS ONLY - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN TURNING IGNITION SWITCH ^ ELECTRICAL - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN TURNING IGNITION SWITCH FORD: 1998-2002 CROWN VICTORIA, MUSTANG, TAURUS 1998-1999 F-250 LD 1998-2001 EXPLORER 1998-2002 E SERIES, EXPEDITION, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT 2001-2002 EXPLORER SPORT TRAC LINCOLN: 1998-2002 CONTINENTAL, TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 1998-2002 GRAND MARQUIS, SABLE 1998-2001 MOUNTAINEER ISSUE Some ignition switch lock cylinder assemblies may exhibit the following highly intermittent conditions: ^ Roughness and/or excessive effort in turning the key from RUN to START position. ^ Key does not fully return from START to RUN after starting vehicle. This may result in intermittent accessory function. ^ Continental ONLY - A malfunction indicator lamp may illuminate with diagnostic trouble codes P0500, P1502 and UlO3g stored in the Powertrain Control Modules (PCM) memory. This may be caused by a Key-In-Ignition warning chime switch. ACTION Replace the KEY-IN-IGNITION WARNING CHIME SWITCH located on the ignition switch lock cylinder with revised pant XL2Z-11A127-AB. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Disconnect the battery ground cable and wait at least one minute. 2. Insent the ignition key and turn it to the RUN position. 3. Insert a punch into the access hole (located in the lower steering column shroud, below the lock cylinder) and press the release button while pulling out the ignition switch lock cylinder. NOTE SOME VEHICLES DO NOT HAVE AN ACCESS HOLE AND REQUIRE LOWER SHROUD REMOVAL. REFER TO THE APPROPRIATE MODEL WORKSHOP MANUAL, IGNITION SWITCH LOCK CYLINDER REMOVAL AND INSTALLATION SECTION 211 IF ADDITIONAL DETAIL IS REQUIRED. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Audible Warning Device: > 01-21-13 > Oct > 01 > Ignition Switch - High Turning Effort/MIL ON/DTC's Set > Page 10610 4. Remove the Plastic Key chime warning switch by prying upward on the plastic retainer, while sliding the switch away from the key insertion end (Figure 1). Refer to the appropriate model Workshop Manual, Key-in-ignition warning switch removal and installation section located in Section 413 if additional detail is required. 5. Install a new Key-In-Ignition warning chime switch XL2Z-11A127-AB and reinstall lock cylinder. 6. Verify proper function of the Ignition Switch Lock Cylinder and Key-In-Ignition warning chime switch. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 012113A Replace The 0.3 Hr. Key-In-Ignition Warning Chime Switch DEALER CODING CONDITION BASIC PART NO. CODE 11A127 42 OASIS CODES: 102000, 112000, 202000, 203000, 204000, 204200, 205000, 206000, 207000, 208000, 208999, 301000, 302000, 497000, 504000, 601300, 603300, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10613 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10614 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10615 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10616 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10617 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10618 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10619 Audible Warning Device: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10620 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10621 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10622 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10623 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10624 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10625 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10626 Diagram 66-1 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > Principles of Operation Audible Warning Device: Description and Operation Principles of Operation The Generic Electronic Module (GEM) and Central Timer Module (CTM) control the following warnings and chimes: - Driver safety belt not fastened (warning lamp and repetitive chime). - Key-in-ignition warning (repetitive chime). - Headlamp-on warning (repetitive chime). - Door ajar (warning lamp and single tone). - Air Bag Redundant (repetitive chime) The following five distinct chime rates are used to indicate warning: - Driver safety belt warning chime is one chime per second. - Key-in-ignition warning is two chimes per second. - Headlamp-on warning is four chimes per second. - Door ajar warning is a single chime. - Air Bag Redundant is five chimes per second. Safety Belt Warning Chime The safety belt warning chime warns the drivers safety belt is not fastened. The safety belt warning chime will sound when the driver safety belt is not fastened or when the ignition switch is turned from the OFF/LOCK or ACC to the RUN or START position. The safety belt warning chime will stop sounding when: The safety belt is fastened. - The ignition switch is switched from RUN or START to the OFF/LOCK or ACC position. - The chime has sounded for six seconds. The safety belt warning chime inputs are: - Ignition switch START position (battery potential on the START [clutch depressed] input) - Ignition switch RUN position (battery potential on RUN and RUN/ACC inputs). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > Principles of Operation > Page 10629 - Driver safety belt switch (grounded when not fastened, open circuit when fastened). Door Ajar Warning Chime The door ajar warning tone warns that a door has become ajar. The door ajar warning tone is a single tone with the duration of one second. The tone will sound when the driver or passenger door initially becomes ajar while the ignition switch is in the RUN position. The door ajar inputs are: Ignition switch RUN position (battery potential on RUN and RUN/ACC inputs). - Door ajar switches (open circuit with door closed, grounded with door ajar). Key-In-Ignition Warning Chime The key-in-ignition warning chime warns that key is still in the ignition when the driver door is ajar. The key-in-ignition warning chime will sound when: Generic Electronic Module (GEM)/Central Timer Module (CTM): Driver door is ajar, the ignition switch is in the OFF/LOCK or ACC position and the key is in the ignition. The key-in-ignition warning chime will stop sounding when: The driver door is closed. - The key is removed from the ignition. - Ignition switch is switched to the RUN position. The key-in-ignition warning chime inputs are: Ignition switch RUN position (battery potential on RUN and RUN/ACC inputs). - Ignition switch ACC position (battery potential on RUN/ACC input only). - Key-in-ignition switch (grounded with key-in-ignition, open circuit key-out). - LH door ajar switch (open circuit with door closed, grounded with door ajar). Headlamps Warning Chime The headlamps warning chime warns that the headlamps are on when all the following conditions are met: The driver door is ajar. - The headlamp switch position is in the PARK or HEAD position. - The ignition switch state is in the OFF/LOCK position. - Key-out. The headlamps warning chime will stop sounding when any one of the conditions above are removed. The headlamps warning chime inputs are: Ignition switch OFF/LOCK position (open circuit on all ignition inputs). Headlamp switch (battery potential in PARK or HEAD position, open circuit when in OFF position). - Driver door ajar switch (open circuit with door closed, grounded with door ajar). - Key-in-ignition switch (grounded with key-in-ignition, open circuit with key-out). Air Bag Redundant Chime The Restraint Control Module (RCM) chime warns that the air bag warning indicator is inoperative or active fault is present within the air bag system. The audible warning format will consist off five sets of tones, in one second increments. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Description and Operation > Principles of Operation > Page 10630 Audible Warning Device: Description and Operation Warning Devices The warning device system consists of the following: - key-in-ignition warning switch - door open warning lamp switch - Central Timer Module (CTM) - Generic Electronic Module (GEM) - driver safety belt switch (integral to the safety belt buckle) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Audible Warning Device: Initial Inspection and Diagnostic Overview 1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical Key-in-ignition warning switch - Door open warning lamp switch - Safety belt warning indicator switch - Headlamp - 4X4 indicator lamp Electrical Central junction box (CJB) Fuse: 6 (5 A) - 8 (5 A) - 15 (5 A) - 20 (5 A) - Battery junction box (BJB) Fuse: 103 (50 A) - Damaged wiring harness - Loose or corroded connections - Generic Electronic Module (GEM)/Central Timer Module (CTM) - Restraint control module (RCM) 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not communicate with the vehicle: Check that the program card is correctly installed. - Check the connections to the vehicle - Check the ignition switch position. 4. If the NGS still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: - CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP - NO RESP/NOT EQUIP for GEM/CTM, go to Pinpoint Test A. See: Pinpoint Tests/A: No Communications With GEM Module - NO RESP/NOT EQUIP for RCM. - SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the RCM, GEM or CTM. 6. If the DTCs retrieved are related to the concern, go to GEM/CTM Module Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10633 Audible Warning Device: Diagnostic Trouble Code Descriptions Part 1 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10634 Part 2 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10635 Part 3 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10636 Part 4 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10637 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10638 Audible Warning Device: Pinpoint Tests Test Notes NOTE: Refer to the wiring diagrams for connector numbers stated in the pinpoint tests. A: No Communications With GEM Module A1 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10639 A2 - A3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10640 A4 - A5 B: Safety Belt Warning Chime Doesn't Operate Correctly Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10641 B1 - B2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10642 B3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10643 B4 - B6 C: Key-In-Ignition Chime Doesn't Operate Properly Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10644 C1 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10645 C2 - C4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10646 C5 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10647 C6 - C7 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10648 D1 - D3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10649 E1 - E2 F: Headlamp on Reminder Chime Doesn't Operate Correctly Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10650 F1 - F2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10651 F3 - F4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10652 F5 - F6 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10653 F7 - F8 G: A Chime Is Inop Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10654 G1 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10655 G2 - G3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10656 G4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10657 Audible Warning Device: Testing and Inspection Initial Inspection and Diagnostic Overview 1. Verify the customer concern. 2. Visually inspect for obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical Key-in-ignition warning switch - Door open warning lamp switch - Safety belt warning indicator switch - Headlamp - 4X4 indicator lamp Electrical Central junction box (CJB) Fuse: 6 (5 A) - 8 (5 A) - 15 (5 A) - 20 (5 A) - Battery junction box (BJB) Fuse: 103 (50 A) - Damaged wiring harness - Loose or corroded connections - Generic Electronic Module (GEM)/Central Timer Module (CTM) - Restraint control module (RCM) 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS menu. If the NGS does not communicate with the vehicle: Check that the program card is correctly installed. - Check the connections to the vehicle - Check the ignition switch position. 4. If the NGS still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: - CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP - NO RESP/NOT EQUIP for GEM/CTM, go to Pinpoint Test A. See: Pinpoint Tests/A: No Communications With GEM Module - NO RESP/NOT EQUIP for RCM. - SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the RCM, GEM or CTM. 6. If the DTCs retrieved are related to the concern, go to GEM/CTM Module Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Diagnostic Trouble Code Descriptions Part 1 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10658 Part 2 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10659 Part 3 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10660 Part 4 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10661 Test Notes NOTE: Refer to the wiring diagrams for connector numbers stated in the pinpoint tests. A: No Communications With GEM Module Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10662 A1 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10663 A2 - A3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10664 A4 - A5 B: Safety Belt Warning Chime Doesn't Operate Correctly Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10665 B1 - B2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10666 B3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10667 B4 - B6 C: Key-In-Ignition Chime Doesn't Operate Properly Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10668 C1 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10669 C2 - C4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10670 C5 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10671 C6 - C7 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10672 D1 - D3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10673 E1 - E2 F: Headlamp on Reminder Chime Doesn't Operate Correctly Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10674 F1 - F2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10675 F3 - F4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10676 F5 - F6 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10677 F7 - F8 G: A Chime Is Inop Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10678 G1 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10679 G2 - G3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10680 G4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10681 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10682 Part 1 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10683 Part 2 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Page 10684 Audible Warning Device: Service and Repair Key In Ignition Warning Switch REMOVAL 1. Remove the ignition switch lock cylinder. 1 Insert the ignition key and turn to the RUN position. 2 Insert a punch in the access hole of the steering column and press the release tab while pulling out the ignition switch lock cylinder. 2. Remove the key-in-ignition warning switch. 1 Pry the clip down. 2 Push the key-in-ignition warning switch off the rear of the ignition switch lock cylinder. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Testing and Inspection > Page 10685 1. To install, reverse the removal procedure. - Verify ignition switch lock cylinder operation. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Testing and Inspection Audible Warning Device Control Module: Testing and Inspection Refer to Instrument Panel/Testing and Inspection/Procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Description and Operation Brake Warning Indicator: Description and Operation The BRAKE indicator will prove out when the ignition switch is placed in the START and then in the RUN position. The BRAKE indicator will also be illuminated when the instrument cluster receives a ground signal from the parking brake switch or the brake fluid level switch. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Charge Lamp/Indicator > Component Information > Description and Operation Charge Lamp/Indicator: Description and Operation The charging system indicator will be illuminated when the generator sends a ground signal to the instrument cluster. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Charge Lamp/Indicator > Component Information > Description and Operation > Page 10695 Charge Lamp/Indicator: Testing and Inspection Refer to Instrument Panel/Testing and Inspection/Procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10700 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10701 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10702 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10703 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10704 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10705 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10706 Cigarette Lighter: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10707 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10708 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10709 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10710 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10711 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10712 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10713 Diagram 44-2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Testing and Inspection Compass: Testing and Inspection Refer to Instrument Panel/Testing and Inspection/Procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. - To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming Deactivation Procedure 1. Disconnect the battery ground cable. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the driver air bag module from the vehicle. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set an air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. 4. Connect an air bag simulator to the vehicle harness at the top of the steering column. 5. Disconnect the passenger air bag module electrical connector. 6. Connect an air bag simulator to the vehicle harness. 7. Reconnect the battery ground cable. Reactivation Procedure 1. Disconnect the battery ground cable. WARNING: The air bag simulators must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the air bag simulator from the vehicle harness connector at the top of the steering column. 4. Install the driver air bag module. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. 5. Remove the air bag simulator from the vehicle harness connector at the passenger air bag module. 6. Connect the passenger air bag module electrical connector. 7. Reconnect the battery ground cable. 8. Prove out the system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 10723 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist should be completed following diagnosis or repair of any air bag system concern. 1. Is the connector at the base of the steering column connected? ................................................................................................................................ [ ] 2. Are the air bag modules connected? ............................................................................................... .......................................................................... [ ] 3. Is the Restraints Control Module (RCM) connected? ............................................................................................................................................... [ ] 4. Is the vehicle battery connected? .................................................................................................... .......................................................................... [ ] Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Description and Operation Dimmer Switch: Description and Operation The panel dimmer switch is integrated into the headlamp switch and controls the interior lamps by activating the interior lamp relay. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Description and Operation Door/Trunk Ajar Indicator/Lamp: Description and Operation The door ajar indicator will prove out when the ignition switch is placed in the START position and then in the RUN position. The door ajar indicator will be illuminated when the CTM/GEM provides a ground signal to the instrument cluster. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Four Wheel Drive Indicator Lamp: Customer Interest Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > Customer Interest: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 10738 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Four Wheel Drive Indicator Lamp: All Technical Service Bulletins Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 10744 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Four Wheel Drive Indicator Lamp: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts Control Module: All Technical Service Bulletins Transfer Case - Inadvertent Shifts Article No. 01-14-1 07/23/01 ^ ELECTRICAL - ELECTRONIC SHIFT ON THE FLY (ESOF) TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS ^ TRANSMISSION - TRANSFER CASE - INADVERTENT 4X4 HI OR LOW SHIFT EVENTS VEHICLES EQUIPPED WITH ELECTRONIC SHIFT ON THE FLY (ESOF) ONLY FORD: 1999 F-250 LD 1999-2001 EXPEDITION, F-150 LINCOLN: 1999-2001 NAVIGATOR ISSUE Some vehicles may exhibit inadvertent 4X4 Hi or Low shift events, 4X4 and/or Low Range indicator flashing or solid or vehicle stuck in 4L after uncommanded shift. This may be caused by the 4X4 shift motor. ACTION Install a YL1Z-7G360-AA shift motor on vehicles built before 12/99. The YL1Z-7G360-AA shift motor with a grey contact plate cover replaces the prior design F75Z-7G360-AA motor with a blue contact plate cover. Grey cover shift motors contain improved sense plate material and shift motor terminal upgrade. For vehicles already equipped with the latest style shift motor, refer to the following Service Procedure for details. SERVICE PROCEDURE For overall description and operation of the Electronic Shift On The Fly (ESOF) Transfer Case refer to Section 308-07 of the appropriate model year Workshop Manual. NOTE ALL DIAGNOSIS BY SYMPTOM SECTIONS HEREIN ARE WRITTEN ASSUMING THAT VEHICLE IS ALREADY EQUIPPED WITH THE LATEST STYLE SHIFT MOTOR. ALWAYS REPLACE SHIFT MOTOR AS A FIRST STEP IF CURRENT MOTOR IS PRIOR LEVEL WITH BLUE COVER. NOTE TO RESET THE GEM'S 4X4 MONITORING SOFTWARE, USE CLEAR DTC COMMAND IN THE NGS OR WOS TESTER (EVEN IF NO DTC'S ARE AVAILABLE) AND CYCLE IGNITION KEY ON-OFF-ON. RECORD ANY CONTINUOUS MEMORY CODES PRIOR TO CLEARING DTCs. NOTE AN UNCOMMANDED 4H OR 4L SHIFT DUE TO FALSE SHIFT MOTOR CONTACT PLATE SIGNAL MAY OR MAY NOT BE ACCOMPANIED BY SHIFT MOTOR DTC'S P1838, P1846, P1850, P1854, P1858, P1866, AND/OR P1867 STORED IN THE GEM DEPENDING ON WHETHER THE IGNITION KEY WAS CYCLED AFTER THE EVENT. NOTE CONTACT PLATE PIDS READ OPPOSITE OF 1999 OR EARLIER WORKSHOP MANUALS WHEN VIEWED WITH NGS RED CARD VERSIONS 15.0 OR LATER. THIS TSB CONTENT REFLECTS USING NGS VERSION 18.0. UNCOMMANDED SHIFT TO 4L 1. Parking Maneuvers/Gear Lever Transitions: Symptoms noted during a lower speed uncommanded shift to 4L event include: ^ Front end binding or hopping while turning ^ Bind feel in drivetrain when backing up and/or turning Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Four Wheel Drive Indicator Lamp: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 10750 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Four Wheel Drive Indicator Lamp: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 10751 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Four Wheel Drive Indicator Lamp: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 10757 ^ Audible clunking or grinding noises, and/or Amber low range light illuminated a. If the Generic Electronic Module (GEM) receives a false Mode Switch input during or shortly after the Digital Transmission Range Sensor (DTR) indicates a Neutral range pass-thru, an uncommanded shift is possible if remaining 4L pre-conditions are met. The pre-conditions besides transmission in Neutral range include: service brake depressed, and vehicle speed less than 5 km/h (3 mph). A false switch input may also set a P1812 or P1815 DTC in the GEM. b. Check mode switch circuits 682 (dark blue) for short to power and 780 (dark blue) for ground short, loose connections at inline connectors, and chafes. c. Monitor Mode Switch Parameter Identification Display (PID) 4WD_SW for false readings while slightly pushing in and wiggling the mode switch knob. Refer to Workshop Manual Section 308-07A for mode switch resistance tests for all switch positions. d. Replace Mode Switch if it fails testing or repair wiring on circuits 682 or 780 if fault indicated. If tests pass, inspect build date stamped on GEM and replace if GEM built prior to 9/98. e. Test drive vehicle for proper 4X4 operation in all modes. Include parking lot maneuvers and transmission gear range lever transitions while testing. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. 2. Road Speed: Reported symptoms for a higher speed uncommanded shift to 4L event include: ^ Rapid deceleration ^ High engine revving possibly accompanied by a P1270 DTC in the PCM ^ Clunk/grind noise ^ Speedometer may spike higher than actual speed. After the initial event the vehicle may exhibit restricted vehicle top speed without 4X4 indicators illuminated but possible MIL (Malfunction Indicator Lamp) on. a. Monitor contact plate A, B, C, D PIDS. With Mode Switch in; ^ A4WD, plate PIDS should read "0C00" ^ 4H PIDS should read "C00C" ^ 4L PIDS should read "C0C0" (sequentially read starting with plate A then B, then C, finally D). If contact plate PIDS DO NOT correspond to the set 4WD position, check for continuity/shorts/moisture/corrosion in the vehicle side of the transfer case shift motor connector (toward the GEM). Visually inspect all terminals, pins, crimps, and connectors closely. Repair any wiring conditions in the contact plate circuits as necessary. b. Road test at speeds above 16 km/h (10 mph) with Mode Switch in both A4WD and 4H to see if the condition returns. Clear DTCs from GEM (even if no DTCs exist) and cycle ignition. Clear DTCs from PCM if a P1270 (engine RPM or vehicle speed limiter reached) code was initially present. UNCOMMANDED SHIFT TO 4H 1. Autolock Strategy (Expedition/Navigator Vehicles Only): Uncommanded 4H shifts with red 4X4 light on "solid" while driving in Automatic Mode may be a vehicle characteristic if driven off-road or under slippery conditions. The GEM Autolock strategy commands transfer case clutch to minimum duty cycle and engages 4H (with mode switch still set to A4WD) to prevent continuous cycling from prematurely wearing the clutch. This is design intent. Excessive tire circumference variations or axles with unmatched gear ratio's can result in unexpected Autolock function as well, for more detail check the speed sensor section below. Once the condition that caused Autolock strategy to activate is no longer present, the system stays in 4H until operator cycles the ignition key or sets the mode switch to 4H then back to A4WD. 2. Transfer Case Speed Sensors (Expedition/Navigator Vehicles Only): If uncommanded shift to 4H occurs on hi-traction surfaces, check TRA_FSP and TRA_RSP PIDS for excessive speed sensor variation between the front and rear transfer case speed sensors. a. If PIDS show sensor inputs not within 2-3 km/h (1-2 mph) of each other during steady-state driving with possible DTCs P1836/P1837, first verify tire pressures, sizes, circumference within 1/4 " among all four tires, and front and rear axle gear ratio's for matching. NOTE Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Four Wheel Drive Indicator Lamp: > 01-14-1 > Jul > 01 > Transfer Case - Inadvertent Shifts > Page 10758 DISCONNECTING CIRCUIT 779 (BROWN) AT MAGNETIC CLUTCH COIL ALLOWS MONITORING SPEED SENSORS WITHOUT CLUTCH ENGAGEMENT INTERFERENCE, AND WILL NOT SET ANY DTCs OR AFFECT DRIVEABILITY. BE SURE TO RECONNECT CIRCUIT WHEN TESTING IS COMPLETED. b. If ratio's match and tire sizes are okay, check associated circuits and replace speed sensor(s) or repair wiring as necessary. c. During sensor installation use lubricant on sensor 0-ring and verify fully seated before tightening hold-down bracket. d. After any repairs, road test while comparing NGS GEM PIDS TRA_FSP and TRA_RSP to PCM VSS signal. Verify all three PIDS match each other within 2-3 km/h (1-2 mph). 3. False Input to GEM A false mode switch input on circuits 682 and/or 780 (Dark Blue) could be interpreted by the GEM as operator requesting a 4H shift. Under this condition, the GEM will command shift motor movement to match the false switch input. The red 4X4 indicator will illuminate just as if operator moved the switch. If the condition became intermittent, the 4X4 range and also the indicators could switch back and forth between A4WD/2H and 4H. a. Check the Mode Switch circuits between the GEM and dash for chafing, shorts, crimps, continuity. Repair wiring if faults found or if wiring okay, replace the Mode Switch itself. b. After any repair, pull DTCs from the GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. STUCK IN 4L AT ALL TIMES 1. If the customer describes an uncommanded shift to 4L shortly after start-up and then unable to shift transfer case, check operation. Associated symptoms could include valid GEM DTCs being erased and false DTCs such as C1107 present. If stuck in 4X4, re-establishing normal shift motor operation is possible by putting mode switch in 4L with trans gear lever in neutral, service brake depressed, and vehicle stationary. To address: a. Replace the GEM module. b. Test drive vehicle. Include a start-up after soak period trying to match the conditions initially reported by the customer to verify the repair. c. Pull DTCs from GEM (even if there are no DTCs available). Clear any codes present and cycle ignition. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 508000, 597997, 610000, 610600, 610700, 612000, 612600, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > 4X4 High Indicator Four Wheel Drive Indicator Lamp: Description and Operation 4X4 High Indicator The 4X4 high indicator will be illuminated when the vehicle is in 4X4 high mode and the GEM sends a ground signal to the instrument cluster. The 4X4 high indicator will prove out when the ignition switch is placed in the START position and then in the RUN position. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > 4X4 High Indicator > Page 10761 Four Wheel Drive Indicator Lamp: Description and Operation Low Range Indicator The LOW RANGE indicator Will be illuminated when the vehicle is in 4X4 low and the Powertrain Control Module (PCM) sends a message to the instrument cluster via the SCP network. The low range indicator will prove out when the ignition switch is placed in the START position and then in the RUN position. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp > Component Information > Description and Operation > Page 10762 Four Wheel Drive Indicator Lamp: Testing and Inspection Refer to Instrument Panel/Testing and Inspection/Procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Description and Operation Fuel Gauge: Description and Operation The instrument cluster receives the fuel level information directly from the fuel sender. When the instrument cluster fails to receive the fuel level signal for more than 33 seconds, then the fuel level gauge will move below E (empty). If the fuel level signal then operates correctly for more than 33 seconds, the fuel gauge will return to the correct position. Fuel fills of less than 22.7 liters (6 gallons) require at least 12 minutes to update the fuel gauge indication. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Description and Operation > Page 10766 Fuel Gauge: Testing and Inspection Refer to Instrument Panel/Testing and Inspection/Procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Headlamp Reminder Indicator > Component Information > Description and Operation Headlamp Reminder Indicator: Description and Operation The high beam indicator will illuminate when the multifunction switch is in the high beam position and sends a battery signal to the instrument cluster. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Headlamp Reminder Indicator > Component Information > Description and Operation > Page 10770 Headlamp Reminder Indicator: Testing and Inspection Refer to Instrument Panel/Testing and Inspection/Procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service Precautions Air Bag(s) Arming and Disarming: Service Precautions WARNING: - To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. - To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming Air Bag(s) Arming and Disarming: Service and Repair Arming and Disarming Deactivation Procedure 1. Disconnect the battery ground cable. WARNING: To avoid accidental deployment and possible personal injury, the backup power supply must be depleted before repairing or replacing any front or side air bag supplemental restraint system (SRS) components and before servicing, replacing, adjusting or striking components near the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers, seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To deplete the backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped). 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the driver air bag module from the vehicle. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. - Do not set an air bag module down with the trim cover face down. This will reduce the risk of injury in the event of an accidental deployment. 4. Connect an air bag simulator to the vehicle harness at the top of the steering column. 5. Disconnect the passenger air bag module electrical connector. 6. Connect an air bag simulator to the vehicle harness. 7. Reconnect the battery ground cable. Reactivation Procedure 1. Disconnect the battery ground cable. WARNING: The air bag simulators must be removed and the air bag modules reconnected when the system is reactivated to avoid non-deployment in a collision, resulting in possible personal injury. 2. Wait at least one minute for the backup power supply in the Restraints Control Module (RCM) to deplete its stored energy. 3. Remove the air bag simulator from the vehicle harness connector at the top of the steering column. 4. Install the driver air bag module. WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your body. This will reduce the risk of injury in the event of an accidental deployment. 5. Remove the air bag simulator from the vehicle harness connector at the passenger air bag module. 6. Connect the passenger air bag module electrical connector. 7. Reconnect the battery ground cable. 8. Prove out the system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Arming and Disarming > Page 10777 Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist The checklist should be completed following diagnosis or repair of any air bag system concern. 1. Is the connector at the base of the steering column connected? ................................................................................................................................ [ ] 2. Are the air bag modules connected? ............................................................................................... .......................................................................... [ ] 3. Is the Restraints Control Module (RCM) connected? ............................................................................................................................................... [ ] 4. Is the vehicle battery connected? .................................................................................................... .......................................................................... [ ] Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Service and Repair Instrument Panel Bulb: Service and Repair REMOVAL 1. Remove the instrument cluster. 2. Remove the necessary instrument cluster bulb(s). Remove the back cover if necessary. INSTALLATION 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 10789 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 10790 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 10791 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 10797 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 10798 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 10799 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Description and Operation Low Fuel Lamp/Indicator: Description and Operation The low fuel indicator will prove out when the ignition switch is placed in the START position and then in the RUN position. The low fuel indicator will illuminate when the fuel level gets low. The instrument cluster receives the fuel level information directly from the fuel sender. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component Information > Description and Operation > Page 10803 Low Fuel Lamp/Indicator: Testing and Inspection Refer to Instrument Panel/Testing and Inspection/Procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator > Component Information > Description and Operation Maintenance Required Lamp/Indicator: Description and Operation SERVICE ENGINE SOON Your vehicle is equipped with a computer that monitors the engine's emission control system. This is commonly known as the On Board Diagnostic System (OBD II). This OBD II system protects the environment by ensuring that your vehicle continues to meet government emission standards. The OBD II system also assists the service technician in properly servicing your vehicle. The SERVICE ENGINE SOON indicator light illuminates when the ignition is first turned to the ON position to check the bulb. If it comes on after the engine is started, on of the engine's emission control systems may be malfunctioning. The light may illuminate without a driveability concern being noted. The vehicle will ususally be drivable and will not require towing. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator > Component Information > Description and Operation > Page 10807 Maintenance Required Lamp/Indicator: Service and Repair Solid SERVICE ENGINE SOON light This means that the On Board Diagnostic System (OBD II) has detected a malfunction. Temporary malfunctions may cause your SERVICE ENGINE SOON light to illuminate. Examples are: 1. The vehicle has run out of fuel. (The engine may misfire or run poorly.) 2. Poor fuel quality or water in the fuel. 3. The fuel cap may not have been properly installed and securely tightened. The temporary malfunctions can be corrected by filling the fuel tank with good quality fuel and/or properly installing and securely tightening the gas cap. After three driving cycles with out these or any other temporary malfunctions present, the SERVICE ENGINE SOON light should turn off. (A driving cycle consists of a cold engine start-up followed by mixed city/highway driving.) No additional vehicle service is required. Blinking SERVICE ENGINE SOON light Engine misfire is occurring which could cause damage to your catalytic converter. You should drive in a moderate fashion (avoid heavy acceleration and deceleration) and have your vehicle serviced at the first available opportunity. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Testing and Inspection Malfunction Indicator Lamp: Testing and Inspection Refer to Instrument Panel/Testing and Inspection/Procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Description and Operation Odometer: Description and Operation The instrument cluster receives odometer rolling count status from the Powertrain Control Module (PCM) and stores the mileage in Non-Volatile Memory (NVM). When the instrument cluster fails to receive the odometer rolling count status for more than two seconds, the odometer display will show dashes. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Description and Operation > Page 10814 Odometer: Testing and Inspection Refer to Instrument Panel/Testing and Inspection/Procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Service and Repair Oil Change Reminder Lamp: Service and Repair NOTE : This vehicle is not equipped with an CHANGE OIL SOON or OIL CHANGE REQUIRED indicator. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Gauge: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference Oil Pressure Gauge: Customer Interest Oil Pressure Sending Unit - Drip Shield Interference Article No. 01-4-2 3/05/01 ENGINE - 5.4L - OIL SENDING UNIT INTERFERENCE FIT AT ENGINE OIL DRIP SHIELD - 4X4 VEHICLES EQUIPPED WITH 5.4L ENGINE ONLY FORD: 1998 F-250 LD 1998-2001 EXPEDITION, F-150 1999-2001 SUPER DUTY F SERIES LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit the engine oil sending unit contacting the oil drip shield attached to the front axle. This may be caused by tight tolerances between the engine oil sending unit and the engine oil drip shield. This may cause a malfunction of the engine oil sending unit. ACTION If the engine oil sending unit needs to be replaced due to contact with the drip shield, modify the engine oil drip shield as shown. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE IF THE ENGINE OIL SENDING UNIT NEEDS TO BE REPLACED IN SERVICE, MODIFY THE ENGINE OIL DRIP SHIELD BEFORE INSTALLING THE NEW ENGINE OIL SENDING UNIT. 1. Remove oil drip shield from front axle. This shield is attached to the front axle by three (3) bolts. 2. Modify shield as shown (Figure 1). Remove excess material from shield. Remove any sharp edges or burrs upon finishing cutting operation. 3. Reinstall engine oil drip shield. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Gauge: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference > Page 10826 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODE OASIS CODES: 401000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Gauge: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference Oil Pressure Gauge: All Technical Service Bulletins Oil Pressure Sending Unit - Drip Shield Interference Article No. 01-4-2 3/05/01 ENGINE - 5.4L - OIL SENDING UNIT INTERFERENCE FIT AT ENGINE OIL DRIP SHIELD - 4X4 VEHICLES EQUIPPED WITH 5.4L ENGINE ONLY FORD: 1998 F-250 LD 1998-2001 EXPEDITION, F-150 1999-2001 SUPER DUTY F SERIES LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit the engine oil sending unit contacting the oil drip shield attached to the front axle. This may be caused by tight tolerances between the engine oil sending unit and the engine oil drip shield. This may cause a malfunction of the engine oil sending unit. ACTION If the engine oil sending unit needs to be replaced due to contact with the drip shield, modify the engine oil drip shield as shown. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE IF THE ENGINE OIL SENDING UNIT NEEDS TO BE REPLACED IN SERVICE, MODIFY THE ENGINE OIL DRIP SHIELD BEFORE INSTALLING THE NEW ENGINE OIL SENDING UNIT. 1. Remove oil drip shield from front axle. This shield is attached to the front axle by three (3) bolts. 2. Modify shield as shown (Figure 1). Remove excess material from shield. Remove any sharp edges or burrs upon finishing cutting operation. 3. Reinstall engine oil drip shield. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Gauge: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference > Page 10832 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODE OASIS CODES: 401000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Technical Service Bulletins > Page 10833 Oil Pressure Gauge: Testing and Inspection Refer to Instrument Panel/Testing and Inspection/Procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Sender: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference Oil Pressure Sender: Customer Interest Oil Pressure Sending Unit - Drip Shield Interference Article No. 01-4-2 3/05/01 ENGINE - 5.4L - OIL SENDING UNIT INTERFERENCE FIT AT ENGINE OIL DRIP SHIELD - 4X4 VEHICLES EQUIPPED WITH 5.4L ENGINE ONLY FORD: 1998 F-250 LD 1998-2001 EXPEDITION, F-150 1999-2001 SUPER DUTY F SERIES LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit the engine oil sending unit contacting the oil drip shield attached to the front axle. This may be caused by tight tolerances between the engine oil sending unit and the engine oil drip shield. This may cause a malfunction of the engine oil sending unit. ACTION If the engine oil sending unit needs to be replaced due to contact with the drip shield, modify the engine oil drip shield as shown. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE IF THE ENGINE OIL SENDING UNIT NEEDS TO BE REPLACED IN SERVICE, MODIFY THE ENGINE OIL DRIP SHIELD BEFORE INSTALLING THE NEW ENGINE OIL SENDING UNIT. 1. Remove oil drip shield from front axle. This shield is attached to the front axle by three (3) bolts. 2. Modify shield as shown (Figure 1). Remove excess material from shield. Remove any sharp edges or burrs upon finishing cutting operation. 3. Reinstall engine oil drip shield. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Technical Service Bulletins > Customer Interest for Oil Pressure Sender: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference > Page 10842 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODE OASIS CODES: 401000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Sender: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference Oil Pressure Sender: All Technical Service Bulletins Oil Pressure Sending Unit - Drip Shield Interference Article No. 01-4-2 3/05/01 ENGINE - 5.4L - OIL SENDING UNIT INTERFERENCE FIT AT ENGINE OIL DRIP SHIELD - 4X4 VEHICLES EQUIPPED WITH 5.4L ENGINE ONLY FORD: 1998 F-250 LD 1998-2001 EXPEDITION, F-150 1999-2001 SUPER DUTY F SERIES LINCOLN: 1998-2001 NAVIGATOR ISSUE Some vehicles may exhibit the engine oil sending unit contacting the oil drip shield attached to the front axle. This may be caused by tight tolerances between the engine oil sending unit and the engine oil drip shield. This may cause a malfunction of the engine oil sending unit. ACTION If the engine oil sending unit needs to be replaced due to contact with the drip shield, modify the engine oil drip shield as shown. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE IF THE ENGINE OIL SENDING UNIT NEEDS TO BE REPLACED IN SERVICE, MODIFY THE ENGINE OIL DRIP SHIELD BEFORE INSTALLING THE NEW ENGINE OIL SENDING UNIT. 1. Remove oil drip shield from front axle. This shield is attached to the front axle by three (3) bolts. 2. Modify shield as shown (Figure 1). Remove excess material from shield. Remove any sharp edges or burrs upon finishing cutting operation. 3. Reinstall engine oil drip shield. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Pressure Sender: > 01-4-2 > Mar > 01 > Oil Pressure Sending Unit - Drip Shield Interference > Page 10848 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. OPERATION/DESCRIPTION/TIME DEALER CODE OASIS CODES: 401000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Technical Service Bulletins > Page 10849 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation Oil Pressure Warning Lamp/Indicator: Description and Operation The low oil pressure indicator on the instrument cluster receives the oil pressure status directly from the oil pressure switch. The two-position oil pressure gauge will display either normal or no oil pressure. The low oil pressure indicator will prove out when the ignition switch is placed in the START position and then in the RUN position. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation > Page 10853 Oil Pressure Warning Lamp/Indicator: Testing and Inspection Refer to Instrument Panel/Testing and Inspection/Procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Testing and Inspection Audible Warning Device Control Module: Testing and Inspection Refer to Instrument Panel/Testing and Inspection/Procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 10866 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 10867 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 10868 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics Keyless Entry Key-Pad: Technical Service Bulletins Keyless Entry - Keypad Diagnostics TSB 06-15-8 08/07/06 KEYPAD DIAGNOSTICS - DEALER INSTALLED ACCESSORY FORD: 1998-2006 Taurus 1999-2003 Escort 1999-2006 Mustang 2000-2006 Focus 2002-2005 Thunderbird 2005-2006 Five Hundred, Freestyle 2006 Crown Victoria, Fusion 1998-2006 Expedition, Explorer, F-150, Ranger 1999 F-250 Light Duty 1999-2003 Windstar 1999-2006 F-Super Duty 2000-2005 Excursion 2000-2006 E-Series 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004 F-150 Heritage 2004-2006 Freestar LINCOLN: 1998-2006 Town Car 2000-2006 Lincoln LS 2006 Zephyr 1998-2006 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006 Mark LT MERCURY: 1998-2005 Sable 1999-2002 Cougar 2005-2006 Montego 2006 Grand Marquis, Milan 1998-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner ISSUE Some vehicles may experience a concern with the keyless entry keypad. In order to properly diagnose the concern with the keyless entry keypad, it is important to identify whether the keypad is a factory installed style (wired) or a Genuine Ford Accessory (GFA) radio frequency (RF) style keypad. ACTION Use the following Service Procedure to identify GFA RF keypads and provide diagnostic service tips. SERVICE PROCEDURE IDENTIFICATION: 1. Production installed keyless entry keypads are mounted flush with the surface of the vehicle and are wired directly to the module controlling the vehicle's keyless entry system. This style keypad can be diagnosed using the appropriate Workshop Manual (WSM), Section 501-14. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 10872 2. Dealer installed GFA RF keypads are adhesive backed and protrude approximately 1/2" (13 mm) from the surface of the vehicle and there are no specific diagnostics available in the WSM (Figure 1). NOTE THIS RF KEYPAD WAS ALSO US[D IN PRODUCTION ON 2004 F-SUPER DUTY VEHICLES BUILT PRIOR TO 12/3/2003. REFER TO WSM, SECTION 501-14 FOR RF KEYPAD DIAGNOSTICS FOR THESE VEHICLES. GENUINE FORD ACCESSORY KEYPAD DIAGNOSTIC TIPS 1. The keypad operates similarly to a remote keyless entry (RKE) transmitter and is programmed using a similar procedure. Although the RF keypad is not specifically addressed in the WSM, the RKE transmitter programming portion of the WSM, Section 501-14 can be used as a guide NOTE THE 7-8 AND 9-0 BUTTONS ON THE KEYPAD MUST BE PRESSED SIMULTANEOUSLY DURING THE PROCEDURE IN ORDER FOR THE KEYPAD TO BE RECOGNIZED AS AN ADDITIONAL REMOTE TRANSMITTER. Since the GFA RF keypad is essentially another RKE transmitter, the transmitter diagnostic pinpoint tests in the vehicle's WSM can also be referenced even though the buttons serving the lock / unlock functions will differ 2. The GFA RF keypad is serviced as an assembly. The internal battery cannot be replaced separately. 3. If the master code or owner selectable code is lost or forgotten, the GFA RF keypad must be replaced. These codes are not stored in any vehicle module (with the exception of 2004 F-Super Duty vehicles produced prior to 12/3/2003). 4. The GFA RF keypad and all RKE transmitters (the number of transmitters allowable will vary by vehicle) must be reprogrammed together anytime the keypad is replaced, an RKE transmitter is replaced, or the module controlling the keyless entry system on the vehicle (GEM/SJB/VSM/DDM etc.) is replaced. NOTE THERE IS AN EXCEPTION TO TIP 4 FOR VEHICLES EQUIPPED WITH INTEGRATED KEYHEAD TRANSMITTERS (IKTs) (FUSION/MILAN/ZEPHYR). THE GFA RF KEYPADS FOR VEHICLES WITH IKTs MUST BE PROGRAMMED INDEPENDENTLY FROM THE IKTs. TURN THE IGNITION FROM "OFF" TO "RUN" 8 TIMES WITHIN 10 SECONDS, WITH THE 8TH TIME ENDING IN "RUN". THE DOOR LOCKS WILL CYCLE TO CONFIRM ENTERING PROGRAMMING MODE. PRESS THE 7-8 AND 9-0 BUTTON ON THE KEYPAD SIMULTANEOUSLY TO SEND A LOCK SIGNAL. TURN IGNITION TO OFF. THE LOCKS WILL CYCLE AGAIN TO INDICATE THE END OF THE PROGRAMMING MODE. 5. The keypad will normally illuminate for 5 seconds after one or more buttons are pressed, and the illumination will immediately turn off if the 7-8 and 9-0 buttons are pressed simultaneously (lock all doors). The keypad contains an optical sensor and will not illuminate under bright lighting conditions. The keypad may only illuminate briefly in colder temperatures in order to maximize the battery power available to transmit a lock/unlock signal. The temperature at which this occurs will vary depending upon the keypad battery age and condition. Both of these conditions are a normal function of the Power Save Mode and do not indicate a need to replace the keypad. 6. After entering the keypad code, the system may unlock the driver's door, lock it, then unlock it again, and the keypad will not even briefly illuminate. This is the Alert Mode and is an indication that battery power is very low and the keypad must be replaced. 7. The keypad also contains an Anti-scan feature. If the wrong code has been entered 7 times (35 consecutive button presses) the keypad is disabled for one minute and the keypad lamp will flash during this time. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 10873 WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 14A626 42 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 06-21-19 > Oct > 06 > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement Technical Service Bulletin # 02-23-4 Date: 021125 Engine Controls - DTC P1635 Set After PCM/IC Replacement Article No. 02-23-4 11/25/02 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2002 MUSTANG 2000-2002 FOCUS 1999-2002 EXPEDITION, F-150 2000-2002 E SERIES 2001-2002 EXPLORER SPORT TRAC, EXPLORER SPORT, RANGER 2002 EXPLORER LINCOLN: 1999-2002 TOWN CAR, NAVIGATOR 2002 BLACKWOOD MERCURY: 2002 MOUNTAINEER Article 02-5-8 is being republished in its entirety to update the Service Procedure and to clarify build dates for Explorer. This article applies to all vehicles listed with the exception of 2002 Explorer. This article applies to 2002 Explorer (SLAP) St. Louis Assembly Plant built before 3/11/2002 and 2002 Explorer (LAP) Louisville Assembly Plant built before 3/4/2002 only. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or Diagnostic Trouble Code (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or Instrument Cluster replacement. This may be caused by the Vehicle Identification (VID) block that must be programmed when replacing the PCM. ACTION As part of the calibration, there is an area referred to as the Vehicle Identification (VID) block. The VID block must be programmed when replacing the PCM. Failure to perform the proper Programmable Module Installation procedure may generate fault code: P1639 VID Block not programmed or is corrupt--P1635 Tire/Axle Out Of Acceptable Range. Refer to the following procedures to ensure the PCM is properly configured. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES:02-5-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 206000, 690000, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 06-21-19 > Oct > 06 > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 10883 Disclaimer Service Procedure NGS Procedure "A" will prevent P1639/P1635 from setting. In the event either code is set, use one of the following NGS Procedures "B" or "C" or WDS Procedure "D" to ensure the PCM is properly configured. NOTE THE FOLLOWING NGS PROCEDURES MUST BE PERFORMED USING THE NGS FLASH CABLE. Procedure A - NGS PREFERRED Method To Prevent P1635/P1639 1. With the original PCM installed and using the NGS service card, select "Programmable Module Installation". 2. Select PCM from the module list. 3. Select "Retrieve Module Config-Old ECU". 4. After the Module data has been stored, install the new PCM, press CANCEL to return to the menu and select "Restore Module Config-New ECU". This procedure will retrieve the VID data from the original PCM and store it into the new PCM. If the original PCM will not communicate, install the new PCM and start the procedure over at Step 1. If the new PCM VID is blank, the NGS will direct you to contact the As-Built Data center during Step a above. Obtain As-Built Data from the Professional Technician Society (PTS) website and manually enter the PCM data from the As-Built Data sheet as the NGS asks for it. After the data has been entered, continue to Step 4 above. Procedure B - NGS Alternative Method 1. Using NGS service card, select "Service Bay Functions". 2. Select PCM from the module list. 3. Select "Module Configuration". 4. Select "94-02 EECV & PTEC-By TSB". 5. Cycle ignition as directed by NGS. 6. Once the PCM initializes and the warning screen is displayed, Tire size/Axle, etc. can then be updated. Procedure C - If the VID block is not correctly programmed - but has some data stored in it, the NGS Service Function Card may not be able to configure the PCM due to the need to reprogram the module 1. Create an NGS Flash Card with the correct calibration (Tear Tag). 2. Start the reprogramming process. (you will be notified that the vehicle already has the latest calibration). 3. Select CANCEL - you will be given the opportunity to update PCM parameters (Vehicle ID block data). 4. Update the Vehicle ID block data and, it necessary, the NGS will continue to reflash the module. Procedure D - WDS Procedure if proper Programmable Module Installation was not performed and P1639/P1635 is set Using WDS with B11 or later software and ignition in OFF position: 1. Connect WDS DLC cable to vehicle OBD II connector (lower center of dash). 2. Select "16 PIN", select "All others, except those below", press TICK. 3. Screen shows installation of cable, press TICK. 4. Screen tells you to turn Ignition ON, DO NOT TURN IGNITION ON. Press TICK. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 06-21-19 > Oct > 06 > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 10884 5. Screen shows progress bar, then screens tells you WDS cannot communicate with the PCM and gives you a "YES" selection and a "NO" selection; select "NO". 6. Make sure the key is still OFF. Press TICK. 7. Screen then shows turn ignition ON, Now turn ignition to ON. 8. Screen shows "The PCM installed to this vehicle is blank". You will be prompted with a list of previous sessions to check if the vehicle was previously identified; press TICK. 9. Select "None of the above". 10. Screen shows "To enable WDS to reprogram the PCM with the correct calibration"; please enter the vehicle calibration number (7 digits) or the tear tag number (4 digits), press TICK. NOTE PCM ENGINEERING NUMBER, CALIBRATION NUMBER AND TEAR TAG NUMBER ARE FOUND ON THE PCM PLASTIC ELECTRICAL CONNECTOR (I.E PCM ENGINEERING NUMBER 1L5F-12A650-MB, TEAR TAG NUMBER RIH1). THE TEAR TAG NUMBER MAY ALSO BE FOUND ON A SQUARE WHITE TAG WITH BLACK LETTERS LOCATED ON THE RIGHT FRONT FENDER AREA NEAR WHERE THE FENDER MEETS THE COWL. 11. Input the PCM engineering number, enter the first (4) digits then select the box at the end of the part number and enter the last (2 or 3) digits of the part number; press TICK. 12. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 13. Screen shows "Remove fuel pump relay and cooling fan relays to prevent electrical interference and battery drain". Press TICK 14. Screen shows "Is vehicle equipped with PATS: Yes or No?" Select correct answer, the screen shows "Please wait" and progress bar moving at bottom of screen. 15. Screen shows "Set ignition switch to ON" - turn ignition to ON. Screen then shows "Downloading data" with a progress bar. 16. Screen shows "Set Ignition switch to OFF", turn ignition OFF then press TICK. 17. Screen shows "This module requires some configuration settings"; manually select those parameters for your vehicle; press TICK. 18. Screen shows "Set Ignition to ON", turn ignition to ON; press TICK. 19. Screen shows selection of parameters: ^ 4X4 low range input - (PCM)? = Yes or No? ^ Manual shift on the fly - (PCM)? = manual or not manual? ^ Tire size? = Selection of tire sizes ^ Axle Ratio? = Selection of axle ratios Choose the correct information for your vehicle; press TICK. NOTE EVEN THOUGH THE PARAMETER APPEARS CORRECTLY PROGRAMMED ON THE WDS SCREEN, YOU MUST MANUALLY RE-SELECT EACH ONE WITH THE CORRECT SELECTION OR WDS WILL NOT CORRECTLY PROGRAM THESE PARAMETERS. 20. Screen shows "Set ignition switch to OFF", turn ignition OFF; press TICK. 21. Screen shows "Set ignition switch to ON"; turn ignition ON. 22. Screen shows "Downloading data", then "Calibration has been loaded and checked"; press Tick. 23. Screen shows "Set ignition switch to OFF", turn ignition to OFF; press TICK. 24. Screen shows "Reinstall Fuel pump relay and cooling fan relays" - Reinstall fuel pump relay; press Tick. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Instrument Panel Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Control Module: > 06-21-19 > Oct > 06 > Customer Interest for Instrument Panel Control Module: > 02-23-4 > Nov > 02 > Engine Controls - DTC P1635 Set After PCM/IC Replacement > Page 10885 25. Screen shows "Install calibration label press TICK. 26. Screen shows "Set ignition switch to ON"; turn ignition ON. 27. Screen shows "At least 2 PATS keys are programmed. PATS initialization is not required"; press TICK. 28. Screen shows "Set ignition switch to OFF"; turn ignition OFF. Disconnect WDS DLC cable from vehicle. Press the ICON at the bottom of the screen with the blue car and folder above it to return back to delete sessions menu. Delete the session and return to main screen on WDS. 29. PCM is now reprogrammed, start engine and confirm MIL light is off. Recheck for DTC's and confirm only P1000 is present. 30. Verify repair. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Module: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Speedometer Module: Customer Interest Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Module: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 10894 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Module: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Speedometer Module: All Technical Service Bulletins Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Module: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 10900 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > Page 10901 Speedometer Module: Testing and Inspection Refer to Instrument Panel/Testing and Inspection/Procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Description and Operation Seat Belt Reminder Lamp: Description and Operation The seat belt switch is hardwired to the Generic Electronic Module (GEM) or Central Timer Module (CTM). The safety belt warning indicator will be illuminated when the GEM/CTM sends a ground signal to the instrument cluster. The safety belt indicator will prove out when the ignition switch is placed in the START position and then in the RUN position. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Description and Operation > Page 10905 Seat Belt Reminder Lamp: Testing and Inspection Refer to Instrument Panel/Testing and Inspection/Procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Description and Operation Dimmer Switch: Description and Operation The panel dimmer switch is integrated into the headlamp switch and controls the interior lamps by activating the interior lamp relay. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Adjustments Shift Indicator: Adjustments 1. Remove the upper instrument panel steering column cover. 2. Place the gearshift lever in the (D) position. - Rotate the gearshift lever clockwise until it bottoms out (first gear), then rotate two detents counterclockwise (D) position). 3. Hang an eight pound weight on the gearshift lever. 4. Center the pointer in the middle of the (D) position. - Rotate the thumb wheel located on the bottom of the steering column to adjust the pointer. 5. Remove the eight pound weight. 6. Carefully move the gearshift lever from detent to detent and compare with transmission settings. Readjust if necessary. 7. Install the upper instrument panel steering column cover. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Description and Operation Speedometer Head: Description and Operation The instrument cluster receives the vehicle speed signal from the Powertrain Control Module (PCM) over the SCP network and displays it on the speedometer gauge. If the instrument cluster receives no vehicle speed signal after one second, the speedometer defaults to 0.0 km/h (0.0 mph). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Description and Operation > Page 10916 Speedometer Head: Testing and Inspection Refer to Instrument Panel/Testing and Inspection/Procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Module > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Module: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Speedometer Module: Customer Interest Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Module > Component Information > Technical Service Bulletins > Customer Interest for Speedometer Module: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 10925 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Module: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Speedometer Module: All Technical Service Bulletins Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 Article No. 00-14-2 Date 7/10/00 ^ DIAGNOSTIC TROUBLE CODE (DTC) - P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT GASOLINE ENGINE VEHICLES ONLY ^ LAMP - 4X4 LAMP ILLUMINATED AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY ^ SPEEDOMETER - INACCURATE AND/OR INOPERATIVE AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT - GASOLINE ENGINE VEHICLES ONLY FORD: 1999-2000 MUSTANG, EXPEDITION, F-150, F-250 2000 ECONOLINE LINCOLN: 1999-2000 TOWN CAR, NAVIGATOR This TSB is being republished in its entirety to update the vehicles affected. ISSUE Some vehicles may exhibit an inoperative or inaccurate speedometer, 4X4 lamp illuminated, and/or Diagnostic Trouble Codes (DTCs) P1635 or P1639 present after a Powertrain Control Module (PCM) or instrument cluster replacement. ACTION This may be caused by the PCM Vehicle Identification (VID) block not being updated. The following Service Procedure should be used along with the Worldwide Diagnostic System (WDS) to update the VID block. SERVICE PROCEDURE 1. To perform this procedure, turn on WDS, wait for full boot-up and undock WDS. 2. Enter user information (will need to have blue car icon at top of screen). 3. Select "16 pin", all except those below, press tic. 4. Make connections as shown, press tic. WDS will display the message "Network Test or Running Data Collection" in the bottom box. When finished, it will display the vehicle configuration; select yes if correct. 5. Enter or skip vehicle/dealer information and press tic. 6. Select the toolbox from the icon menu. 7. Select Module Programming and press tic. 8. Select Programmable Parameters, Powertrain and press tic. A list will pop up displaying VID block options that can be changed. The options include Tire Size, Axle Ratio, 4X4/4X2, and manual/electronic shift on the fly (ESOF). The formula for revolutions per mile (rev/mile) is 63,360 divided by the circumference of the tire in inches. 9. Select the correct attributes per vehicle application and follow WDS prompts to complete procedure. 10. Once the VID has been updated, clear any codes and test-drive to verify procedure was accepted. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-12-2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Module: > 00-14-2 > Jul > 00 > Speedometer Defective,, 4X4 Lamp ON, DTCs P1635/P1639 > Page 10931 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage And Emissions Warranty Coverage OPERATION DESCRIPTION TIME 001402A Reprogram Vehicle 0.6 Hr. Identification (VID)/Speedometer Using Worldwide Diagnostic System (WDS) DEALER CODING CONDITION BASIC PART NO. CODE 12A650 42 OASIS CODES: 203000, 203200, 204000, 204100, 204200, 206000, 508000, 601300, 602300, 603300, 613000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Module > Component Information > Technical Service Bulletins > Page 10932 Speedometer Module: Testing and Inspection Refer to Instrument Panel/Testing and Inspection/Procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Suspension Warning Indicator > Component Information > Description and Operation Suspension Warning Indicator: Description and Operation The CK SUSP indicator will be illuminated if the instrument cluster receives a ground signal from the air suspension control module. The air suspension indicator will prove out when the ignition switch is placed in the START position and then in the RUN position. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Suspension Warning Indicator > Component Information > Description and Operation > Page 10936 Suspension Warning Indicator: Testing and Inspection Refer to Instrument Panel/Testing and Inspection/Procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Testing and Inspection Tachometer: Testing and Inspection Refer to Instrument Panel/Testing and Inspection/Procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Description and Operation Temperature Gauge: Description and Operation Engine coolant temperature information is received by the instrument cluster from the Powertrain Control Module (PCM) over the SCP network. Temperatures over 121°C (275°F) will display hot (H). If the engine coolant temperature data is missing or invalid for five seconds, the instrument cluster will move the engine coolant temperature gauge below the cold (C) position. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Description and Operation > Page 10943 Temperature Gauge: Testing and Inspection Refer to Instrument Panel/Testing and Inspection/Procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Specifications Temperature Sensor (Gauge): Specifications Temperature Sender 20 Nm Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Specifications > Page 10947 Temperature Sensor (Gauge): Service and Repair Removal All Engines 1. Partially drain the cooling system. 4.6L Engines 2. Disconnect the connector and remove the water temperature indicator sender unit. 5.4L Engines 3. Disconnect the connector and remove the water temperature indicator sender unit. Installation 1. To install, reverse the removal procedure. - Fill the cooling system. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Testing and Inspection Volt Meter Gauge: Testing and Inspection Refer to Instrument Panel/Testing and Inspection/Procedures. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Specifications Ambient Light Sensor: Specifications Light Sensor Amplifier Screws ................................................................................................................................................ 2.1-2.9 Nm (18.5-25.6 in lbs) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Customer Interest for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling Brake Lamp: Customer Interest A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Customer Interest for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 10967 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling Brake Lamp: All Technical Service Bulletins A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 10973 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Page 10974 Brake Lamp: Specifications Rear Lamp Bolts .................................................................................................................................. .................................... 2.7-3.7 Nm (23.8-32.7 in lbs) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions Brake Lamp: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10977 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10978 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10979 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10980 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10981 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10982 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10983 Brake Lamp: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10984 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10985 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10986 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10987 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10988 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10989 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10990 Brake Lamp: Electrical Diagrams Diagram 90-1 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10991 Diagram 90-2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10992 Diagram 90-3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 10993 Diagram 90-4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis Brake Lamp: Flow of Diagnosis 1. Verify the customer concern by operating the stoplamps. 2. Visually inspect for the following obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Damaged Brake Pedal Position (BPP) switch Electrical ^ Central Junction Box (CJB) Fuse 13 (15A) ^ Damaged wiring harness ^ Loose or corroded connections ^ Damaged stoplamp bulb 3. If the concern is not visually evident, determine the symptom and proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10996 Brake Lamp: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the stoplamps. 2. Visually inspect for the following obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Damaged Brake Pedal Position (BPP) switch Electrical ^ Central Junction Box (CJB) Fuse 13 (15A) ^ Damaged wiring harness ^ Loose or corroded connections ^ Damaged stoplamp bulb 3. If the concern is not visually evident, determine the symptom and proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10997 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10998 Brake Lamp: Pinpoint Tests Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 10999 K1 - K2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11000 L1 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11001 L2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11002 M1 - M3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Page 11003 73 Digital Multimeter Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Service and Repair Brake Light Switch: Service and Repair REMOVAL 1. Disconnect the Brake Pedal Position (BPP) switch connector. 2. Remove the BPP switch. 1 Remove the self-locking pin. 2 Remove the spacer. 3 Remove the BPP switch. INSTALLATION 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > Customer Interest: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling Center Mounted Brake Lamp: Customer Interest A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > Customer Interest: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 11015 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling Center Mounted Brake Lamp: All Technical Service Bulletins A/T - Inadvertent Shift Interlock Disabling Article No. 02-17-6 09/02/02 LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997 F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003 EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003 SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE, EXPLORER SPORT TRAC LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS 1998-2003 NAVIGATOR MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE 1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle line applications. ISSUE Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These added "police lights" have the potential to disable the brake shift interlock system. The brake shift interlock feature prevents the vehicle from being shifted from park unless the brake pedal is depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears. ACTION As appropriate, dealers should advise owners (including corporate, municipal, and police agencies) that any vehicle that has been modified with a connection to the brake circuit, or that electrically interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the emergency lighting system should be modified in a manner that does not interfere with normal service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety Standards Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 11021 (FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the brakes. Installation of warning lights should only be performed with a completely separate electrical system, without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module (PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle malfunction. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Center Mounted Brake Lamp: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator Radiator: All Technical Service Bulletins A/T Cooler - Fluid Leaks at Radiator Article No. 00-9-1 DATE 5/1/00 TITLE LEAK - TRANSMISSION FLUID LEAKS AT RADIATOR - VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSION AND TRANSMISSION OIL COOLER IN RADIATOR END TANK FORD: 1997-2000 MUSTANG, EXPEDITION, EXPLORER, F-150, F-250 LD 1998-2000 RANGER 1999-2000 SUPER DUTY F SERIES LINCOLN: 1998-2000 NAVIGATOR MERCURY: 1998-2000 MOUNTAINEER This TSB is being republished in its entirety to update the vehicles affected and to update the Service Procedure. ISSUE Transmission fluid may leak between the radiator transmission oil cooler and the transmission oil cooler fitting (NOT the cooler line into the fitting), which may result in a residue of transmission fluid on the radiator tank around the transmission oil cooler fitting. This may be caused by insufficient thread sealer on the transmission oil cooler fitting. NOTE: THIS TSB DOES NOT APPLY TO TRANSMISSION FLUID LEAKAGE AT THE TRANSMISSION LINE TO TRANSMISSION OIL COOLER FITTING. ACTION Install O-ring W705181-S onto the transmission oil cooler fitting. The O-ring is designed to seal the leak and reduce the possibility of transmission fluid leakage. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Verify that transmission fluid is leaking between the transmission oil cooler and the transmission oil cooler fitting (NOT the transmission cooler line fitting into the transmission oil cooler fitting). Refer to Figure 1. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Center Mounted Brake Lamp: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 11027 2. Remove the radiator from the vehicle following Workshop Manual procedure. Place the radiator on a flat surface so that the transmission oil cooler fittings are facing upward. Refer to Figure 2. 3. Clean the area around the transmission oil cooler fitting. This will insure that contaminants do not enter the transmission oil cooler when the transmission oil cooler fittings are removed. CAUTION: OIL-BASED SOLVENTS AND CLEANERS SHOULD NOT BE USED WHEN CLEANING THE RADIATOR. OIL-BASED SOLVENTS AND CLEANERS CAN DAMAGE THE RADIATOR END TANK SEALS AND CAUSE LEAKS. 4. Remove the upper transmission oil cooler fitting. NOTE: REMOVE ONLY ONE (1) TRANSMISSION OIL COOLER FITTING AT A TIME, OTHERWISE THE COOLER MAY DROP INTO THE RADIATOR. 5. Once the fitting is removed from the transmission oil cooler, verify that there is a gasket between the transmission oil cooler and the inside of the radiator tank. If there is no gasket, replace the radiator. If the gasket is in place, continue to Step 6. 6. Inspect the transmission oil cooler fitting threads for damage. If the threads are damaged, replace the radiator. If the threads show no sign of damage, continue to Step 7. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Center Mounted Brake Lamp: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 11028 7. Install O-ring W705181-S on the transmission oil cooler fitting. Refer to Figures 2 and 3. CAUTION: THREAD SEALANT OR TAPE SHOULD NEVER BE USED ON THE THREADS OF THE TRANSMISSION OIL COOLER FITTING. THE USE OF SUCH MATERIALS WILL CREATE A LEAK PATH. 8. Making sure that the gasket between the transmission oil cooler and the inside of the radiator tank is still in place, reinstall the transmission oil cooler fitting. The fitting should be torqued to 38-45 N.m (28-33 lb-ft). NOTE:: DO NOT USE AIR TOOLS TO TORQUE THE TRANSMISSION OIL COOLER FITTING. USE A HAND-OPERATED TORQUE WRENCH ONLY. 9. Repeat Steps 2-8 for the other transmission oil cooler fitting. This fitting should also have the O-ring replaced even if it is not leaking. 10. Make sure that no radiator coolant has entered the transmission oil cooler. Reinstall the radiator in the vehicle following Workshop Manual procedure. 11. Verify that both the transmission and the engine cooling system have the proper fluid levels outlined in the Workshop Manual. PARTS INFORMATION LABOR OPERATION APPLICATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Center Mounted Brake Lamp: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 11029 OTHER APPLICABLE ARTICLES: NONE SUPERCEDES: 99-4-6 WARRANTY STATUS OPERATION DESCRIPTION DEALER CODING OASIS CODES: 402000, 510000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Center Mounted Brake Lamp: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 11035 2. Remove the radiator from the vehicle following Workshop Manual procedure. Place the radiator on a flat surface so that the transmission oil cooler fittings are facing upward. Refer to Figure 2. 3. Clean the area around the transmission oil cooler fitting. This will insure that contaminants do not enter the transmission oil cooler when the transmission oil cooler fittings are removed. CAUTION: OIL-BASED SOLVENTS AND CLEANERS SHOULD NOT BE USED WHEN CLEANING THE RADIATOR. OIL-BASED SOLVENTS AND CLEANERS CAN DAMAGE THE RADIATOR END TANK SEALS AND CAUSE LEAKS. 4. Remove the upper transmission oil cooler fitting. NOTE: REMOVE ONLY ONE (1) TRANSMISSION OIL COOLER FITTING AT A TIME, OTHERWISE THE COOLER MAY DROP INTO THE RADIATOR. 5. Once the fitting is removed from the transmission oil cooler, verify that there is a gasket between the transmission oil cooler and the inside of the radiator tank. If there is no gasket, replace the radiator. If the gasket is in place, continue to Step 6. 6. Inspect the transmission oil cooler fitting threads for damage. If the threads are damaged, replace the radiator. If the threads show no sign of damage, continue to Step 7. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Center Mounted Brake Lamp: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 11036 7. Install O-ring W705181-S on the transmission oil cooler fitting. Refer to Figures 2 and 3. CAUTION: THREAD SEALANT OR TAPE SHOULD NEVER BE USED ON THE THREADS OF THE TRANSMISSION OIL COOLER FITTING. THE USE OF SUCH MATERIALS WILL CREATE A LEAK PATH. 8. Making sure that the gasket between the transmission oil cooler and the inside of the radiator tank is still in place, reinstall the transmission oil cooler fitting. The fitting should be torqued to 38-45 N.m (28-33 lb-ft). NOTE:: DO NOT USE AIR TOOLS TO TORQUE THE TRANSMISSION OIL COOLER FITTING. USE A HAND-OPERATED TORQUE WRENCH ONLY. 9. Repeat Steps 2-8 for the other transmission oil cooler fitting. This fitting should also have the O-ring replaced even if it is not leaking. 10. Make sure that no radiator coolant has entered the transmission oil cooler. Reinstall the radiator in the vehicle following Workshop Manual procedure. 11. Verify that both the transmission and the engine cooling system have the proper fluid levels outlined in the Workshop Manual. PARTS INFORMATION LABOR OPERATION APPLICATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Center Mounted Brake Lamp: > 00-9-1 > May > 00 > A/T Cooler - Fluid Leaks at Radiator > Page 11037 OTHER APPLICABLE ARTICLES: NONE SUPERCEDES: 99-4-6 WARRANTY STATUS OPERATION DESCRIPTION DEALER CODING OASIS CODES: 402000, 510000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical Service Bulletins > Page 11038 Center Mounted Brake Lamp: Specifications Rear Hi-Mount Lamp Screws .................................................................................................................................................. 1.6-2.2 Nm (14.1-19.4 in lbs) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Relay > Component Information > Locations Courtesy Lamp Relay: Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Relay > Component Information > Locations > Page 11043 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Relay > Component Information > Locations > Page 11044 Courtesy Lamp Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Relay > Component Information > Locations > Page 11045 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Technical Service Bulletins > Battery Saver Relay - Malfunction Glove Box Lamp: Technical Service Bulletins Battery Saver Relay - Malfunction Article No. 00-19-2 09/18/00 ^ LAMP - COURTESY, GLOVE COMPARTMENT, UNDERHOOD, RUNNING BOARD LAMPS INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES ^ POWER WINDOWS - INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES ^ RADIO - INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES ^ REAR WIPER - INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES FORD: 1999-2000 EXPEDITION, F-150, F-250 LD LINCOLN: 1999-2000 NAVIGATOR This article is being republished in its entirety to update the part number. ISSUE A temporary loss of functions controlled by the battery saver relay may occur on some vehicles. These functions may be inoperative for a short period of time after the vehicle has sat unattended for at least 45 minutes. These functions are limited to courtesy and interior/demand lamps, glove compartment, underhood lamps and power windows. Running board lights, moonroof and the rear wiper may be affected on Expedition and Navigator. The radio may also be inoperative during this time on Navigator only. The loss of these features is temporary and can last from a few seconds up to 10-15 minutes. ACTION Replace the Battery Saver Relay (YL3Z-14N089-AA). Refer to the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) for location of this relay. NOTE PERMANENT LOSS OF ANY OF THESE FUNCTIONS SHOULD NOT BE ADDRESSED WITH THIS TSB. FUNCTIONS OTHER THAN THOSE EXPLICITLY MENTIONED ABOVE THAT ARE REPORTED TO BE INOPERATIVE SHOULD NOT BE ADDRESSED WITH THIS TSB. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-8-7 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION / DESCRIPTION / TIME Table Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Technical Service Bulletins > Battery Saver Relay - Malfunction > Page 11050 DEALER CODING OASIS CODES: 10200, 204000, 201100, 201200, 202000, 20300, 205000, 207000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Interior Light Switch > Component Information > Service and Repair Interior Light Switch: Service and Repair Switch - Interior Lamp Removal 1. Remove the front door trim panel. Please refer to Body and Frame/Doors, Hood and Trunk/Door/Door Panel/Service and Repair/ See: Body and Frame/Doors, Hood and Trunk/Doors 2. Remove the interior lamp switch. a. Disconnect the interior lamp switch electrical connector. b. Rotate interior lamp switch counterclockwise and remove. Installation 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Diagrams > Page 11058 Daytime Running Lamp Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Relay > Component Information > Diagrams > Page 11059 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Description and Operation Dimmer Switch: Description and Operation The panel dimmer switch is integrated into the headlamp switch and controls the interior lamps by activating the interior lamp relay. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Technical Service Bulletins > Battery Saver Relay - Malfunction Battery Discharge Protection Relay: Technical Service Bulletins Battery Saver Relay - Malfunction Article No. 00-19-2 09/18/00 ^ LAMP - COURTESY, GLOVE COMPARTMENT, UNDERHOOD, RUNNING BOARD LAMPS INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES ^ POWER WINDOWS - INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES ^ RADIO - INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES ^ REAR WIPER - INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES FORD: 1999-2000 EXPEDITION, F-150, F-250 LD LINCOLN: 1999-2000 NAVIGATOR This article is being republished in its entirety to update the part number. ISSUE A temporary loss of functions controlled by the battery saver relay may occur on some vehicles. These functions may be inoperative for a short period of time after the vehicle has sat unattended for at least 45 minutes. These functions are limited to courtesy and interior/demand lamps, glove compartment, underhood lamps and power windows. Running board lights, moonroof and the rear wiper may be affected on Expedition and Navigator. The radio may also be inoperative during this time on Navigator only. The loss of these features is temporary and can last from a few seconds up to 10-15 minutes. ACTION Replace the Battery Saver Relay (YL3Z-14N089-AA). Refer to the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) for location of this relay. NOTE PERMANENT LOSS OF ANY OF THESE FUNCTIONS SHOULD NOT BE ADDRESSED WITH THIS TSB. FUNCTIONS OTHER THAN THOSE EXPLICITLY MENTIONED ABOVE THAT ARE REPORTED TO BE INOPERATIVE SHOULD NOT BE ADDRESSED WITH THIS TSB. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-8-7 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION / DESCRIPTION / TIME Table Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Technical Service Bulletins > Battery Saver Relay - Malfunction > Page 11067 DEALER CODING OASIS CODES: 10200, 204000, 201100, 201200, 202000, 20300, 205000, 207000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Technical Service Bulletins > Page 11068 Battery Discharge Protection Relay: Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Technical Service Bulletins > Page 11069 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Technical Service Bulletins > Page 11070 Battery Discharge Protection Relay: Description and Operation The following components are under the control of the battery saver relay: ^ Delayed accessory relay. ^ Overhead interior lamp with map lamps. ^ Underhood lamp switch. ^ Glove box lamp switch. ^ Overhead interior lamp switch. ^ Interior lamp relay coil. The battery saver relay becomes active (relay coil is energized) when the GEM is in awake mode and is deactivated (relay coil is de-energized) in sleep mode. The battery saver will remain active until the ignition state is not ACC or RUN and 45 minutes have passed since last active input. At that time, the relay will be deactivated and power to the above circuits will terminate. Five minutes after the battery saver relay has become deactivated, the GEM will go into a lower power state known as sleep mode. In the sleep mode, the GEM will deactivate all outputs and will monitor select inputs. Logical characteristics of the GEM battery saver mode are as follows: Feature Inputs: ^ Sleep/Awake mode status. Feature Outputs: ^ Battery saver relay control (Open circuit in sleep mode, grounded when awake). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Technical Service Bulletins > Page 11071 Battery Discharge Protection Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Technical Service Bulletins > Page 11072 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Switch > Component Information > Service and Repair Dome Lamp Switch: Service and Repair Switch - Interior Lamp Removal 1. Remove the front door trim panel. Please refer to Body and Frame/Doors, Hood and Trunk/Door/Door Panel/Service and Repair/ See: Body and Frame/Doors, Hood and Trunk/Doors 2. Remove the interior lamp switch. a. Disconnect the interior lamp switch electrical connector. b. Rotate interior lamp switch counterclockwise and remove. Installation 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information > Service Precautions > Technician Safety Information Fog/Driving Lamp Bulb: Technician Safety Information WARNING: THE HALOGEN BULB CONTAINS GAS UNDER PRESSURE. THE BULB MAY SHATTER IF THE GLASS ENVELOPE IS SCRATCHED OR IF THE BULB IS DROPPED. HANDLE THE BULB ONLY BY ITS BASE. AVOID TOUCHING THE GLASS ENVELOPE . Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information > Service Precautions > Technician Safety Information > Page 11082 Fog/Driving Lamp Bulb: Vehicle Damage Warnings NOTE: The fog lamp bulb should not be removed from the fog lamp until just before a replacement bulb is installed. Removing the bulb for an extended period of time may affect fog lamp bulb performance. Contaminants may enter the fog lamp where they can settle on the lens and reflector. Never turn on the fog lamps with the bulb removed. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information > Service Precautions > Page 11083 Fog/Driving Lamp Bulb: Service and Repair REMOVAL WARNING: THE HALOGEN BULB CONTAINS GAS UNDER PRESSURE. THE BULB MAY SHATTER IF THE GLASS ENVELOPE IS SCRATCHED OR IF THE BULB IS DROPPED. HANDLE THE BULB ONLY BY ITS BASE. AVOID TOUCHING THE GLASS ENVELOPE. NOTE: The fog lamp bulb should not be removed from the fog lamp until just before a replacement bulb is installed. Removing the bulb for an extended period of time may affect fog lamp bulb performance. Contaminants may enter the fog lamp where they can settle on the lens and reflector. Never turn on the fog lamps with the bulb removed. 1. Disconnect the battery ground cable. 2. Disconnect the fog lamp bulb electrical connector. 3. Rotate the fog lamp socket counterclockwise and remove. INSTALLATION 1. To install, reverse the removal procedure. WARNING: THE HALOGEN BULB CONTAINS GAS UNDER PRESSURE. THE BULB MAY SHATTER IF THE GLASS ENVELOPE IS SCRATCHED OR IF THE BULB IS DROPPED. HANDLE THE BULB ONLY BY ITS BASE. AVOID TOUCHING THE GLASS ENVELOPE. NOTE: ^ The fog lamp bulb should not be removed from the fog lamp until just before a replacement bulb is installed. Removing the bulb for an extended period of time may affect fog lamp bulb performance. Contaminants may enter the fog lamp where they can settle on the lens and reflector. Never turn on the fog lamps with the bulb removed from the fog lamp. ^ When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Lens > Component Information > Specifications Fog/Driving Lamp Lens: Specifications Fog Lamp Bolts ................................................................................................................................... ........................................................ 11 Nm (8 ft lbs) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Lens > Component Information > Specifications > Page 11087 Fog/Driving Lamp Lens: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the fog lamp bulb electrical connector. 3. Remove the fog lamp assembly. 1 Remove the bolts. 2 Remove the fog lamp assembly. 4. Remove the fog lamp. 1 Remove the fog lamp retainers. 2 Remove the fog lamp. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Lens > Component Information > Specifications > Page 11088 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 11092 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 11093 Fog/Driving Lamp Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information > Locations > Page 11094 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Service and Repair Fog/Driving Lamp Switch: Service and Repair REMOVAL AND INSTALLATION The fog lamp switch is integral to the headlamp switch. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions Hazard Warning Switch: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11107 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11108 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11109 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11110 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11111 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11112 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11113 Hazard Warning Switch: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11114 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11115 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11116 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11117 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11118 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11119 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11120 Hazard Warning Switch: Electrical Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Page 11121 Hazard Warning Switch: Description and Operation The integrated multifunction switch is mounted to the LH side of the steering column and controls the turn signal, headlamp dimmer/flash-to-pass, windshield wiper/washer and hazard warning. The ignition switch is mounted below the steering column and is activated using the ignition key and rotating the key lock cylinder on the steering column. If equipped with manual transmission, the key release lever prevents rotation of the ignition cylinder to LOCK or ACC positions unless the lever is depressed. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis Hazard Warning Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11124 Hazard Warning Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11125 Hazard Warning Switch: Diagnostic Trouble Code Descriptions GEM/CTM Active Command Index Part 1 Of 2 Part 2 Of 2 GEM/CTM Diagnostic Trouble Code (DTC) Index Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11126 Part 1 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11127 Part 2 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11128 Part 3 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11129 Part 4 Of 4 GEM/CTM Parameter Identification (PID) Index Part 1 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11130 Part 2 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11131 Part 3 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11132 Hazard Warning Switch: Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11133 Hazard Warning Switch: Testing and Inspection Flow of Diagnosis 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Initial Inspection and Diagnostic Overview Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11134 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures GEM/CTM Active Command Index Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11135 Part 1 Of 2 Part 2 Of 2 GEM/CTM Diagnostic Trouble Code (DTC) Index Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11136 Part 1 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11137 Part 2 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11138 Part 3 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11139 Part 4 Of 4 GEM/CTM Parameter Identification (PID) Index Part 1 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11140 Part 2 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11141 Part 3 Of 3 Symptom Related Diagnostic Procedures Part 1 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11142 Part 2 Of 2 Test A: No Communication With the GEM or CTM Test A1 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11143 Test A2 - A3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11144 Test A4 - A5 Test B: Unable to Enter Self-Test Test B1 Test C: Ignition Switch Is Inoperative Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11145 Test C1 Test D: No Power In ACC Test D1 Test E: No Power In Run Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11146 Test E1 Test E1 - E2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11147 Test F: No Power In Start Test F1 - F2 Component Tests and General Diagnostics Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11148 Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11149 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Page 11150 Hazard Warning Switch: Service and Repair MULTIFUNCTION SWITCH Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1. Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2. Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder 3. Twist the tilt wheel handle and shank and remove. 4. NOTE: Move gear selector to lowest position to access steering column opening cover. Release the four clips and remove the steering column opening cover. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Page 11151 5. Remove the upper and lower steering column shrouds. 1. Remove the three screws. 2. Remove the lower steering column shroud. 3. Remove the upper steering column shroud. 6. Remove the mult1 function switch. 1. Remove the two screws. 2. Disconnect the electrical connectors. 3. Remove the mult1 function switch. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Testing and Inspection > Page 11152 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service Precautions > Technician Safety Information Headlamp Bulb: Technician Safety Information WARNING: THE HALOGEN BULB CONTAINS GAS UNDER PRESSURE. THE BULB MAY SHATTER IF THE GLASS ENVELOPE IS SCRATCHED OR IF THE BULB IS DROPPED. HANDLE THE BULB ONLY BY ITS BASE. AVOID TOUCHING THE GLASS ENVELOPE . Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service Precautions > Technician Safety Information > Page 11158 Headlamp Bulb: Vehicle Damage Warnings NOTE: The headlamp bulb should not be removed from the headlamp until just before a replacement bulb is installed. Removing the bulb for an extended period of time may affect headlamp bulb performance. Contaminants may enter the headlamp where they can settle on the lens and reflector. Never turn on the headlamps with the bulb removed from the headlamp. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service Precautions > Page 11159 Headlamp Bulb: Service and Repair REMOVAL WARNING: THE HALOGEN BULB CONTAINS GAS UNDER PRESSURE. THE BULB MAY SHATTER IF THE GLASS ENVELOPE IS SCRATCHED OR IF THE BULB IS DROPPED. HANDLE THE BULB ONLY BY ITS BASE. AVOID TOUCHING THE GLASS ENVELOPE. NOTE: The headlamp bulb should not be removed from the headlamp until just before a replacement bulb is installed. Removing the bulb for an extended period of time may affect headlamp bulb performance. Contaminants may enter the headlamp where they can settle on the lens and reflector. Never turn on the headlamps with the bulb removed from the headlamp. 1. Disconnect the battery ground cable. 2. Remove the headlamp assembly. 1 Raise the headlamp retainers by pushing rearward and pulling up. 2 Disconnect the headlamp electrical connector. 3 Remove the headlamp assembly. 3. Rotate the headlamp bulb retainer counterclockwise and remove. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service Precautions > Page 11160 4. Remove the headlamp bulb. INSTALLATION 1. To install, reverse the removal procedure. ^ Adjust the headlamp. See: Adjustments WARNING: THE HALOGEN BULB CONTAINS GAS UNDER PRESSURE. THE BULB MAY SHATTER IF THE GLASS ENVELOPE IS SCRATCHED OR IF THE BULB IS DROPPED. HANDLE THE BULB ONLY BY ITS BASE. AVOID TOUCHING THE GLASS ENVELOPE. NOTE: ^ The headlamp bulb should not be removed from the headlamp until just before a replacement bulb is installed. Removing the bulb for an extended period of time may affect headlamp bulb performance. Contaminants may enter the headlamp where they can settle on the lens and reflector. Never turn on the headlamps with the bulb removed from the headlamp. ^ Be sure the headlamp assembly is positioned correctly with the alignment pins inserted into the proper holes and onto the ribs of the reinforcement. ^ When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Control Module > Component Information > Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations > Page 11167 Headlamp Dimmer Switch: Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations > Page 11168 Headlamp Dimmer Switch: Description and Operation The integrated multifunction switch is mounted to the LH side of the steering column and controls the turn signal, headlamp dimmer/flash-to-pass, windshield wiper/washer and hazard warning. The ignition switch is mounted below the steering column and is activated using the ignition key and rotating the key lock cylinder on the steering column. If equipped with manual transmission, the key release lever prevents rotation of the ignition cylinder to LOCK or ACC positions unless the lever is depressed. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis Headlamp Dimmer Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11171 Headlamp Dimmer Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11172 Headlamp Dimmer Switch: Diagnostic Trouble Code Descriptions GEM/CTM Active Command Index Part 1 Of 2 Part 2 Of 2 GEM/CTM Diagnostic Trouble Code (DTC) Index Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11173 Part 1 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11174 Part 2 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11175 Part 3 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11176 Part 4 Of 4 GEM/CTM Parameter Identification (PID) Index Part 1 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11177 Part 2 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11178 Part 3 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11179 Headlamp Dimmer Switch: Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11180 Headlamp Dimmer Switch: Testing and Inspection Flow of Diagnosis 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Initial Inspection and Diagnostic Overview Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11181 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures GEM/CTM Active Command Index Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11182 Part 1 Of 2 Part 2 Of 2 GEM/CTM Diagnostic Trouble Code (DTC) Index Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11183 Part 1 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11184 Part 2 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11185 Part 3 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11186 Part 4 Of 4 GEM/CTM Parameter Identification (PID) Index Part 1 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11187 Part 2 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11188 Part 3 Of 3 Symptom Related Diagnostic Procedures Part 1 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11189 Part 2 Of 2 Test A: No Communication With the GEM or CTM Test A1 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11190 Test A2 - A3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11191 Test A4 - A5 Test B: Unable to Enter Self-Test Test B1 Test C: the Ignition Switch Is Inoperative Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11192 Test C1 Test D: No Power In ACC Test D1 Test E: No Power In Run Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11193 Test E1 Test E1 - E2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11194 Test F: No Power In Start Test F1 - F2 Component Tests and General Diagnostics Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11195 Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11196 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 11197 Headlamp Dimmer Switch: Service and Repair MULTIFUNCTION SWITCH Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1. Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2. Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder 3. Twist the tilt wheel handle and shank and remove. 4. NOTE: Move gear selector to lowest position to access steering column opening cover. Release the four clips and remove the steering column opening cover. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 11198 5. Remove the upper and lower steering column shrouds. 1. Remove the three screws. 2. Remove the lower steering column shroud. 3. Remove the upper steering column shroud. 6. Remove the mult1 function switch. 1. Remove the two screws. 2. Disconnect the electrical connectors. 3. Remove the mult1 function switch. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 11199 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 11203 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 11204 Headlamp Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations > Page 11205 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams Headlamp Switch: Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 11209 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 11210 Headlamp Switch: Testing and Inspection Component Testing Procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 11211 Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 11212 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 11213 Headlamp Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Turn the headlamp switch knob to the headlamp position and pull the knob. 3. Insert a thin tool to release the headlamp switch knob and remove. 4. Turn the headlamp switch knob 180 degrees and install. 5. Turn counterclockwise until the back of the headlamp switch knob is in the OFF position. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 11214 6. Turn the headlamp switch knob fully clockwise. 7. Remove the headlamp switch. 1 Pull the headlamp switch from the instrument panel. 2 Disconnect the electrical connectors. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Horn Relay: Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 11219 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 11220 Horn Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 11221 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Service and Repair Horn Switch: Service and Repair NOTE: The steering wheel pad horn switch is part of the driver side air bag module. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Interior Lighting Relay > Component Information > Description and Operation Interior Lighting Relay: Description and Operation The GEM and the CTM control the interior lamps and illuminated entry function with the interior lamp relay. The relay is activated by applying ground to the relay coil through GEM C267-15, and is deactivated by removing the ground signal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions License Plate Lamp: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11232 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11233 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11234 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11235 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11236 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11237 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11238 License Plate Lamp: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11239 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11240 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11241 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11242 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11243 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11244 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11245 License Plate Lamp: Electrical Diagrams Diagram 92-1 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11246 Diagram 92-2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis License Plate Lamp: Flow of Diagnosis 1. Verify the customer concern by operating the parking lamps. 2. Visually inspect for the following obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Damaged multifunction switch ^ Damaged headlamp switch Electrical ^ Battery Junction Box (BJB) Fuse 7 (15A) ^ Central Junction Box (CJB) Fuse 4 (5A) ^ Damaged wiring harness ^ Loose or corroded connections ^ Damaged parking lamp relay ^ Damaged parking, rear or license lamp 3. If the concern is not visually evident, determine the symptom and proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11249 License Plate Lamp: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the parking lamps. 2. Visually inspect for the following obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Damaged multifunction switch ^ Damaged headlamp switch Electrical ^ Battery Junction Box (BJB) Fuse 7 (15A) ^ Central Junction Box (CJB) Fuse 4 (5A) ^ Damaged wiring harness ^ Loose or corroded connections ^ Damaged parking lamp relay ^ Damaged parking, rear or license lamp 3. If the concern is not visually evident, determine the symptom and proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11250 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11251 License Plate Lamp: Pinpoint Tests Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11252 R1 - R2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11253 S1 - S2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11254 S3 - S4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11255 T1 - T2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11256 U1 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11257 U2 - U3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11258 73 Digital Multimeter Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Map Light > Map Light Bulb > Component Information > Service and Repair Map Light Bulb: Service and Repair REMOVAL 1. Remove the map lamp assembly. 2. Release the clip on the bulb(s) to be replaced. 3. Remove the map lamp bulb. 1 Remove the map lamp reflector. 2 Remove the map lamp bulb from the Clips. INSTALLATION 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions Marker Lamp: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11267 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11268 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11269 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11270 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11271 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11272 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11273 Marker Lamp: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11274 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11275 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11276 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11277 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11278 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11279 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11280 Marker Lamp: Electrical Diagrams Diagram 92-1 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11281 Diagram 92-2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Page 11286 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Page 11287 Parking Lamp Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations > Page 11288 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Technical Service Bulletins > Battery Saver Relay - Malfunction Battery Discharge Protection Relay: Technical Service Bulletins Battery Saver Relay - Malfunction Article No. 00-19-2 09/18/00 ^ LAMP - COURTESY, GLOVE COMPARTMENT, UNDERHOOD, RUNNING BOARD LAMPS INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES ^ POWER WINDOWS - INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES ^ RADIO - INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES ^ REAR WIPER - INOPERATIVE IN MORNING OR AFTER VEHICLE IS LEFT UNATTENDED FOR 45 MINUTES FORD: 1999-2000 EXPEDITION, F-150, F-250 LD LINCOLN: 1999-2000 NAVIGATOR This article is being republished in its entirety to update the part number. ISSUE A temporary loss of functions controlled by the battery saver relay may occur on some vehicles. These functions may be inoperative for a short period of time after the vehicle has sat unattended for at least 45 minutes. These functions are limited to courtesy and interior/demand lamps, glove compartment, underhood lamps and power windows. Running board lights, moonroof and the rear wiper may be affected on Expedition and Navigator. The radio may also be inoperative during this time on Navigator only. The loss of these features is temporary and can last from a few seconds up to 10-15 minutes. ACTION Replace the Battery Saver Relay (YL3Z-14N089-AA). Refer to the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) for location of this relay. NOTE PERMANENT LOSS OF ANY OF THESE FUNCTIONS SHOULD NOT BE ADDRESSED WITH THIS TSB. FUNCTIONS OTHER THAN THOSE EXPLICITLY MENTIONED ABOVE THAT ARE REPORTED TO BE INOPERATIVE SHOULD NOT BE ADDRESSED WITH THIS TSB. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-8-7 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION / DESCRIPTION / TIME Table Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Technical Service Bulletins > Battery Saver Relay - Malfunction > Page 11294 DEALER CODING OASIS CODES: 10200, 204000, 201100, 201200, 202000, 20300, 205000, 207000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Technical Service Bulletins > Page 11295 Battery Discharge Protection Relay: Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Technical Service Bulletins > Page 11296 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Technical Service Bulletins > Page 11297 Battery Discharge Protection Relay: Description and Operation The following components are under the control of the battery saver relay: ^ Delayed accessory relay. ^ Overhead interior lamp with map lamps. ^ Underhood lamp switch. ^ Glove box lamp switch. ^ Overhead interior lamp switch. ^ Interior lamp relay coil. The battery saver relay becomes active (relay coil is energized) when the GEM is in awake mode and is deactivated (relay coil is de-energized) in sleep mode. The battery saver will remain active until the ignition state is not ACC or RUN and 45 minutes have passed since last active input. At that time, the relay will be deactivated and power to the above circuits will terminate. Five minutes after the battery saver relay has become deactivated, the GEM will go into a lower power state known as sleep mode. In the sleep mode, the GEM will deactivate all outputs and will monitor select inputs. Logical characteristics of the GEM battery saver mode are as follows: Feature Inputs: ^ Sleep/Awake mode status. Feature Outputs: ^ Battery saver relay control (Open circuit in sleep mode, grounded when awake). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Technical Service Bulletins > Page 11298 Battery Discharge Protection Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information > Technical Service Bulletins > Page 11299 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations Courtesy Lamp Relay: Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations > Page 11303 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations > Page 11304 Courtesy Lamp Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations > Page 11305 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Page 11309 Daytime Running Lamp Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Relay > Component Information > Diagrams > Page 11310 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations Fog/Driving Lamp Relay: Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 11314 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 11315 Fog/Driving Lamp Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay > Component Information > Locations > Page 11316 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 11323 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 11324 Headlamp Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations > Page 11325 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 11329 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 11330 Horn Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 11331 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Relay > Component Information > Description and Operation Interior Lighting Relay: Description and Operation The GEM and the CTM control the interior lamps and illuminated entry function with the interior lamp relay. The relay is activated by applying ground to the relay coil through GEM C267-15, and is deactivated by removing the ground signal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 11338 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 11339 Parking Lamp Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay > Component Information > Locations > Page 11340 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Regular Production Option Relay Block Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Regular Production Option Relay Block > Page 11345 Trailer Lighting Relay: Locations Trailer Running Lamps Relay Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Regular Production Option Relay Block > Page 11346 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Regular Production Option Relay Block > Page 11347 Trailer Lighting Relay: Locations Trailer Tow Battery Charge Relay Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Regular Production Option Relay Block > Page 11348 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Regular Production Option Relay Block > Page 11349 Trailer Lighting Relay: Locations Trailer Tow Reversing Lamp Relay Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Regular Production Option Relay Block > Page 11350 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 11351 Trailer Lighting Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 11352 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Specifications Ambient Light Sensor: Specifications Light Sensor Amplifier Screws ................................................................................................................................................ 2.1-2.9 Nm (18.5-25.6 in lbs) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Service and Repair Brake Light Switch: Service and Repair REMOVAL 1. Disconnect the Brake Pedal Position (BPP) switch connector. 2. Remove the BPP switch. 1 Remove the self-locking pin. 2 Remove the spacer. 3 Remove the BPP switch. INSTALLATION 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 00-9-6 > May > 00 > Windshield Wipers - Operate While Switch is OFF Combination Switch: Customer Interest Windshield Wipers - Operate While Switch is OFF Article No. 00-9-6 DATE 5/1/00 TITLE WINDSHIELD WIPERS - FRONT WIPERS OPERATE WHILE SWITCH IS IN "OFF" POSITION FORD: 1999 TAURUS 1999-2000 MUSTANG, EXPLORER, F-150, F-250 LD, RANGER, WINDSTAR 2000 EXCURSION MERCURY: 1999 SABLE 1999-2000 MOUNTAINEER This TSB is being republished in its entirety to revise the vehicles affected and to update the Service Procedure. This TSB applies to the following vehicles only: Explorer, Mountaineer and Ranger 4X2 Without Power Windows built through 9/12/1999 Excursion built through 8/25/1999 F-150/250, Mustang, Windstar, Taurus/Sable built through 8/16/1999 ISSUE The front windshield wipers may operate while the multifunction switch is in the OFF position on some vehicles. This may be caused by a resistance drift in the multifunction switch or a partially plugged-in connector. ACTION If the uncommanded wiper operation condition is present and all wiper related connectors are fully seated, install a revised multifunction switch. Refer to the following Service Procedure and the Multifunction Switch Application Chart for the applicable switch. SERVICE PROCEDURE NOTE: DO NOT ATTEMPT TO REPAIR THE VEHICLE BY REPLACING THE GENERIC ELECTRONIC MODULE (GEM) OR THE WIPER CONTROL MODULE. NOTE: MAKE SURE THAT ALL CONNECTIONS ARE FULLY SEATED TO THE GEM, CENTER INSTRUMENT PANEL COMPONENTS, FRONT WIPER MOTOR AND MULTIFUNCTION SWITCH DURING INSTALLATION. CHECK THE MULTIFUNCTION SWITCH CONNECTION CLOSELY FOR LOOSE CONNECTIONS, TERMINALS, AND TERMINAL PUSH OUTS. DO NOT ATTEMPT A CONTINUITY CHECK OR PROBE THE CIRCUITS OF THE WIRE HARNESS. If non-wiper related symptoms are present, perform diagnostics per the appropriate Workshop Manual. If the uncommanded wiper operation condition is present and no other symptoms apply to the vehicle being serviced, install a revised multifunction switch. Refer to the Multifunction Switch Application Chart for the applicable switch. NOTE: MAKE SURE THAT ALL CONNECTIONS ARE FULLY SEATED DURING INSTALLATION. DO NOT ATTEMPT TO REPAIR THE VEHICLE BY REPLACING THE GEM OR THE WIPER CONTROL MODULE. Using Worldwide Diagnostic System (WDS), New Generation Star (NGS) Jester or Service Bay Diagnostic System (SBDS), run GEM or CTM. Retrieve and clear continuous Diagnostic Trouble Codes (DTCs) and run On-Demand Self-Test to make sure that no valid DTCs are set. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 00-9-6 > May > 00 > Windshield Wipers - Operate While Switch is OFF > Page 11371 MALFUNCTION SWITCH APPLICATION PARTS SUPERSEDES: 99-24-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 202000, 203000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 00-9-6 > May > 00 > Windshield Wipers - Operate While Switch is OFF Combination Switch: All Technical Service Bulletins Windshield Wipers - Operate While Switch is OFF Article No. 00-9-6 DATE 5/1/00 TITLE WINDSHIELD WIPERS - FRONT WIPERS OPERATE WHILE SWITCH IS IN "OFF" POSITION FORD: 1999 TAURUS 1999-2000 MUSTANG, EXPLORER, F-150, F-250 LD, RANGER, WINDSTAR 2000 EXCURSION MERCURY: 1999 SABLE 1999-2000 MOUNTAINEER This TSB is being republished in its entirety to revise the vehicles affected and to update the Service Procedure. This TSB applies to the following vehicles only: Explorer, Mountaineer and Ranger 4X2 Without Power Windows built through 9/12/1999 Excursion built through 8/25/1999 F-150/250, Mustang, Windstar, Taurus/Sable built through 8/16/1999 ISSUE The front windshield wipers may operate while the multifunction switch is in the OFF position on some vehicles. This may be caused by a resistance drift in the multifunction switch or a partially plugged-in connector. ACTION If the uncommanded wiper operation condition is present and all wiper related connectors are fully seated, install a revised multifunction switch. Refer to the following Service Procedure and the Multifunction Switch Application Chart for the applicable switch. SERVICE PROCEDURE NOTE: DO NOT ATTEMPT TO REPAIR THE VEHICLE BY REPLACING THE GENERIC ELECTRONIC MODULE (GEM) OR THE WIPER CONTROL MODULE. NOTE: MAKE SURE THAT ALL CONNECTIONS ARE FULLY SEATED TO THE GEM, CENTER INSTRUMENT PANEL COMPONENTS, FRONT WIPER MOTOR AND MULTIFUNCTION SWITCH DURING INSTALLATION. CHECK THE MULTIFUNCTION SWITCH CONNECTION CLOSELY FOR LOOSE CONNECTIONS, TERMINALS, AND TERMINAL PUSH OUTS. DO NOT ATTEMPT A CONTINUITY CHECK OR PROBE THE CIRCUITS OF THE WIRE HARNESS. If non-wiper related symptoms are present, perform diagnostics per the appropriate Workshop Manual. If the uncommanded wiper operation condition is present and no other symptoms apply to the vehicle being serviced, install a revised multifunction switch. Refer to the Multifunction Switch Application Chart for the applicable switch. NOTE: MAKE SURE THAT ALL CONNECTIONS ARE FULLY SEATED DURING INSTALLATION. DO NOT ATTEMPT TO REPAIR THE VEHICLE BY REPLACING THE GEM OR THE WIPER CONTROL MODULE. Using Worldwide Diagnostic System (WDS), New Generation Star (NGS) Jester or Service Bay Diagnostic System (SBDS), run GEM or CTM. Retrieve and clear continuous Diagnostic Trouble Codes (DTCs) and run On-Demand Self-Test to make sure that no valid DTCs are set. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 00-9-6 > May > 00 > Windshield Wipers - Operate While Switch is OFF > Page 11377 MALFUNCTION SWITCH APPLICATION PARTS SUPERSEDES: 99-24-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 202000, 203000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Dome Lamp Switch > Component Information > Service and Repair Dome Lamp Switch: Service and Repair Switch - Interior Lamp Removal 1. Remove the front door trim panel. Please refer to Body and Frame/Doors, Hood and Trunk/Door/Door Panel/Service and Repair/ See: Body and Frame/Doors, Hood and Trunk/Doors 2. Remove the interior lamp switch. a. Disconnect the interior lamp switch electrical connector. b. Rotate interior lamp switch counterclockwise and remove. Installation 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Service and Repair Fog/Driving Lamp Switch: Service and Repair REMOVAL AND INSTALLATION The fog lamp switch is integral to the headlamp switch. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions Hazard Warning Switch: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11389 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11390 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11391 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11392 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11393 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11394 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11395 Hazard Warning Switch: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11396 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11397 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11398 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11399 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11400 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11401 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11402 Hazard Warning Switch: Electrical Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Page 11403 Hazard Warning Switch: Description and Operation The integrated multifunction switch is mounted to the LH side of the steering column and controls the turn signal, headlamp dimmer/flash-to-pass, windshield wiper/washer and hazard warning. The ignition switch is mounted below the steering column and is activated using the ignition key and rotating the key lock cylinder on the steering column. If equipped with manual transmission, the key release lever prevents rotation of the ignition cylinder to LOCK or ACC positions unless the lever is depressed. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis Hazard Warning Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11406 Hazard Warning Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11407 Hazard Warning Switch: Diagnostic Trouble Code Descriptions GEM/CTM Active Command Index Part 1 Of 2 Part 2 Of 2 GEM/CTM Diagnostic Trouble Code (DTC) Index Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11408 Part 1 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11409 Part 2 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11410 Part 3 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11411 Part 4 Of 4 GEM/CTM Parameter Identification (PID) Index Part 1 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11412 Part 2 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11413 Part 3 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11414 Hazard Warning Switch: Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11415 Hazard Warning Switch: Testing and Inspection Flow of Diagnosis 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Initial Inspection and Diagnostic Overview Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11416 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures GEM/CTM Active Command Index Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11417 Part 1 Of 2 Part 2 Of 2 GEM/CTM Diagnostic Trouble Code (DTC) Index Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11418 Part 1 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11419 Part 2 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11420 Part 3 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11421 Part 4 Of 4 GEM/CTM Parameter Identification (PID) Index Part 1 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11422 Part 2 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11423 Part 3 Of 3 Symptom Related Diagnostic Procedures Part 1 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11424 Part 2 Of 2 Test A: No Communication With the GEM or CTM Test A1 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11425 Test A2 - A3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11426 Test A4 - A5 Test B: Unable to Enter Self-Test Test B1 Test C: Ignition Switch Is Inoperative Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11427 Test C1 Test D: No Power In ACC Test D1 Test E: No Power In Run Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11428 Test E1 Test E1 - E2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11429 Test F: No Power In Start Test F1 - F2 Component Tests and General Diagnostics Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11430 Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11431 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Page 11432 Hazard Warning Switch: Service and Repair MULTIFUNCTION SWITCH Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1. Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2. Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder 3. Twist the tilt wheel handle and shank and remove. 4. NOTE: Move gear selector to lowest position to access steering column opening cover. Release the four clips and remove the steering column opening cover. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Page 11433 5. Remove the upper and lower steering column shrouds. 1. Remove the three screws. 2. Remove the lower steering column shroud. 3. Remove the upper steering column shroud. 6. Remove the mult1 function switch. 1. Remove the two screws. 2. Disconnect the electrical connectors. 3. Remove the mult1 function switch. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Testing and Inspection > Page 11434 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 11438 Headlamp Dimmer Switch: Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations > Page 11439 Headlamp Dimmer Switch: Description and Operation The integrated multifunction switch is mounted to the LH side of the steering column and controls the turn signal, headlamp dimmer/flash-to-pass, windshield wiper/washer and hazard warning. The ignition switch is mounted below the steering column and is activated using the ignition key and rotating the key lock cylinder on the steering column. If equipped with manual transmission, the key release lever prevents rotation of the ignition cylinder to LOCK or ACC positions unless the lever is depressed. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis Headlamp Dimmer Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11442 Headlamp Dimmer Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11443 Headlamp Dimmer Switch: Diagnostic Trouble Code Descriptions GEM/CTM Active Command Index Part 1 Of 2 Part 2 Of 2 GEM/CTM Diagnostic Trouble Code (DTC) Index Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11444 Part 1 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11445 Part 2 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11446 Part 3 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11447 Part 4 Of 4 GEM/CTM Parameter Identification (PID) Index Part 1 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11448 Part 2 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11449 Part 3 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11450 Headlamp Dimmer Switch: Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11451 Headlamp Dimmer Switch: Testing and Inspection Flow of Diagnosis 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Initial Inspection and Diagnostic Overview Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11452 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures GEM/CTM Active Command Index Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11453 Part 1 Of 2 Part 2 Of 2 GEM/CTM Diagnostic Trouble Code (DTC) Index Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11454 Part 1 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11455 Part 2 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11456 Part 3 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11457 Part 4 Of 4 GEM/CTM Parameter Identification (PID) Index Part 1 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11458 Part 2 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11459 Part 3 Of 3 Symptom Related Diagnostic Procedures Part 1 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11460 Part 2 Of 2 Test A: No Communication With the GEM or CTM Test A1 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11461 Test A2 - A3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11462 Test A4 - A5 Test B: Unable to Enter Self-Test Test B1 Test C: the Ignition Switch Is Inoperative Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11463 Test C1 Test D: No Power In ACC Test D1 Test E: No Power In Run Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11464 Test E1 Test E1 - E2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11465 Test F: No Power In Start Test F1 - F2 Component Tests and General Diagnostics Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11466 Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11467 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 11468 Headlamp Dimmer Switch: Service and Repair MULTIFUNCTION SWITCH Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1. Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2. Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder 3. Twist the tilt wheel handle and shank and remove. 4. NOTE: Move gear selector to lowest position to access steering column opening cover. Release the four clips and remove the steering column opening cover. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 11469 5. Remove the upper and lower steering column shrouds. 1. Remove the three screws. 2. Remove the lower steering column shroud. 3. Remove the upper steering column shroud. 6. Remove the mult1 function switch. 1. Remove the two screws. 2. Disconnect the electrical connectors. 3. Remove the mult1 function switch. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Testing and Inspection > Page 11470 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams Headlamp Switch: Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 11474 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 11475 Headlamp Switch: Testing and Inspection Component Testing Procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 11476 Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 11477 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 11478 Headlamp Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Turn the headlamp switch knob to the headlamp position and pull the knob. 3. Insert a thin tool to release the headlamp switch knob and remove. 4. Turn the headlamp switch knob 180 degrees and install. 5. Turn counterclockwise until the back of the headlamp switch knob is in the OFF position. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 11479 6. Turn the headlamp switch knob fully clockwise. 7. Remove the headlamp switch. 1 Pull the headlamp switch from the instrument panel. 2 Disconnect the electrical connectors. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Service and Repair Horn Switch: Service and Repair NOTE: The steering wheel pad horn switch is part of the driver side air bag module. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Service and Repair Interior Light Switch: Service and Repair Switch - Interior Lamp Removal 1. Remove the front door trim panel. Please refer to Body and Frame/Doors, Hood and Trunk/Door/Door Panel/Service and Repair/ See: Body and Frame/Doors, Hood and Trunk/Doors 2. Remove the interior lamp switch. a. Disconnect the interior lamp switch electrical connector. b. Rotate interior lamp switch counterclockwise and remove. Installation 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 11489 Turn Signal Switch: Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 11490 Turn Signal Switch: Description and Operation The integrated multifunction switch is mounted to the LH side of the steering column and controls the turn signal, headlamp dimmer/flash-to-pass, windshield wiper/washer and hazard warning. The ignition switch is mounted below the steering column and is activated using the ignition key and rotating the key lock cylinder on the steering column. If equipped with manual transmission, the key release lever prevents rotation of the ignition cylinder to LOCK or ACC positions unless the lever is depressed. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis Turn Signal Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11493 Turn Signal Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11494 Turn Signal Switch: Diagnostic Trouble Code Descriptions GEM/CTM Diagnostic Trouble Code (DTC) Index Part 1 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11495 Part 2 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11496 Part 3 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11497 Part 4 Of 4 GEM/CTM Active Command Index Part 1 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11498 Part 2 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11499 Turn Signal Switch: Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11500 Turn Signal Switch: Testing and Inspection Flow of Diagnosis 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Initial Inspection and Diagnostic Overview Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11501 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures GEM/CTM Diagnostic Trouble Code (DTC) Index Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11502 Part 1 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11503 Part 2 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11504 Part 3 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11505 Part 4 Of 4 GEM/CTM Active Command Index Part 1 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11506 Part 2 Of 2 Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11507 Component Tests and General Diagnostics Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11508 Schematic Pinout Values and Diagnostic Parameters Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11509 Part 1 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11510 Part 2 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11511 Part 3 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Page 11512 Turn Signal Switch: Service and Repair MULTIFUNCTION SWITCH Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1. Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2. Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder 3. Twist the tilt wheel handle and shank and remove. 4. NOTE: Move gear selector to lowest position to access steering column opening cover. Release the four clips and remove the steering column opening cover. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Page 11513 5. Remove the upper and lower steering column shrouds. 1. Remove the three screws. 2. Remove the lower steering column shroud. 3. Remove the upper steering column shroud. 6. Remove the mult1 function switch. 1. Remove the two screws. 2. Disconnect the electrical connectors. 3. Remove the mult1 function switch. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Testing and Inspection > Page 11514 Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Revised Article No. 01-21-6 10/29/01 ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE MERCURY HOOD LAMP SWITCH FORD: 1987-1995 TAURUS 1988-1991 CROWN VICTORIA 1989 THUNDERBIRD 1989-1996 MUSTANG 1994-1996 THUNDERBIRD 1990 BRONCO II 1990-1996 RANGER 1991-1996 BRONCO 1994-2001 EXPLORER 1997-2001 F-150 2000-2001 EXCURSION 2002 EXPEDITION LINCOLN: 1989-1994 CONTINENTAL 1990-1992 MARK VII 1990-1996 TOWN CAR 1993-1995 MARK VIII 2002 NAVIGATOR MERCURY: 1987-1995 SABLE 1988-1991 GRAND MARQUIS 1989 COUGAR 1994-1996 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is to provide information on replacement hood lamp switches. The 27 degree Mercury style hood switches will no longer be available. Replacement 27 degree Mechanical switches will be available as a service replacement. ACTION For vehicles requiring hood lamp switch replacement, replace the 27 degree Mercury switch with new 27 degree Mechanical switch. Replace hood lamp switch per the appropriate model year Workshop Manual as needed. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised > Page 11519 OASIS CODES: 201000, 201200 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Specifications Tail Lamp: Specifications Rear Lamp Bolts .................................................................................................................................. .................................... 2.7-3.7 Nm (23.8-32.7 in lbs) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions Tail Lamp: Diagram Information and Instructions How to Find and Use These Diagrams Diagrams are presented in three main categories: - Power Distribution Diagrams - System Diagrams - Grounds Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11525 Diagram 13-7 (Sample Power Distribution Diagram Page) Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered. The power distribution source is shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the component/system being powered near the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. The power distribution diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the top of the Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11526 diagram pages within the system diagrams. Diagram 85-1 (Sample System Diagram Page) System Diagrams Components that work together are shown together in a system/subsystem diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a diagram page. All wires, connectors, components, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11527 Diagram 10-1 (Sample Grounds Diagram Page) Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This information is useful for checking interconnections of the grounding circuits of different systems. The components/systems being grounded are shown at the top of a diagram page. All wires, connectors, and splices are shown in the same manner that the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked with large arrow heads indicating which diagram page the circuit went to/came from. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11528 The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by following the hyperlinks at the bottom of the diagram pages within the system diagrams. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11529 Electrical Symbols Wire Color Code Identification Wire and connector colors are listed as follows (standard Ford color abbreviations are used): COLOR ABBREVIATIONS BU Blue NA Natural BK Black OG Orange Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11530 BN Brown PK Pink DB Dark Blue VT Purple DG Dark Green RD Red GN Green SR Silver GY Gray TN Tan LB Light Blue WH White LG Light Green YE Yellow Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire, and the second color listed is the stripe marking of the wire. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11531 Tail Lamp: Diagnostic Aids HOW TO FIND ELECTRICAL CONCERNS TROUBLESHOOTING STEPS These six steps present an orderly method of troubleshooting. Step 1. Verify the concern. - Operate the complete system to check the accuracy and completeness of the customer's complaint. Step 2. Narrow the concern. - Using the wiring diagrams, narrow down the possible causes and locations of the concern to pinpoint the exact cause. - Read the description notes at the components and study the wiring schematic. You should then know enough about the circuit operation to determine where to check for the trouble. Step 3. Test the suspected cause. - Use electrical test procedures to find the specific cause of the symptoms. - The component location reference bars and the pictures will help you find components. Component location information for connectors, diodes, resistors, splices and grounds can be found at Vehicle Locations. Step 4. Verify the cause. - Confirm that you have found the correct cause by connecting jumper wires and/or temporarily installing a known good component and operating the circuit. Step 5. Make the repair. - Repair or replace the inoperative component. Step 6. Verify the repair. - Operate the system as in Step 1 and check that your repair has removed all symptoms without creating any new symptoms. Some engine circuits may need special test equipment and special procedures. See Testing and Inspection for the specific component, system, or sub-system in question. NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level; only a few component tests are provided by OE. TROUBLESHOOTING TOOLS JUMPER WIRE This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to complete a circuit. WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and ground. This direct battery short may cause injury or fire. VOLTMETER A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and positive (+ or red) lead to voltage measuring point. OHMMETER An Ohmmeter shows the resistance between two connected points. TEST LAMP Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11532 A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check. SELF-POWERED TEST LAMP The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground Check. CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit during testing. Hot circuits can cause equipment damage and false readings. In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to power the load. If jumpering the terminals powers the circuit, the switch is inoperative. CONTINUITY CHECK (Locating open circuits) Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if circuit is closed. Switches and fuses can be checked in the same way. VOLTAGE CHECK Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for voltage by touching the other lead to the test Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11533 point. Bulb goes on when the test point has voltage. SHORT CHECK A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other loads powered through the fuse: - Motors: disconnect motor connector (Connector C4). - Lights: remove bulbs. 3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This step is just a check to be sure you have power to the circuit) 5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of the fuse at the connector of the disconnected component. (Connect the test lamp lead to connector C4). If the Test Lamp is off, the short is in the disconnected component. - If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X, the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the short is between C2 and C3. GROUND CHECK Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground and the frame. Any indicated voltage means that the ground is inoperative. Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK. DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge can help narrow the concern to a specific area. For example, if several circuits fail at the same time, check for a common power or ground connection (see Power and Ground Distribution Diagrams). If part of a Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11534 circuit fails, check the connections between the part that works and the part that doesn't work. For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't work, then power and ground paths must be good. Since the dimmer switch is the component that switches this power to the high beam lights and indicator, it is most likely the cause of failure. TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS The following illustrations are known examples of wiring harness, splices and connectors that will create intermittent electrical concerns. The concerns are hidden and can only be discovered by a physical evaluation as shown in each illustration. NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated terminal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11535 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11536 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11537 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11538 Tail Lamp: Electrical Diagrams Diagram 92-1 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 11539 Diagram 92-2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis Tail Lamp: Flow of Diagnosis 1. Verify the customer concern by operating the parking lamps. 2. Visually inspect for the following obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Damaged multifunction switch ^ Damaged headlamp switch Electrical ^ Battery Junction Box (BJB) Fuse 7 (15A) ^ Central Junction Box (CJB) Fuse 4 (5A) ^ Damaged wiring harness ^ Loose or corroded connections ^ Damaged parking lamp relay ^ Damaged parking, rear or license lamp 3. If the concern is not visually evident, determine the symptom and proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11542 Tail Lamp: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the parking lamps. 2. Visually inspect for the following obvious signs of mechanical and electrical damage. VISUAL INSPECTION CHART Mechanical ^ Damaged multifunction switch ^ Damaged headlamp switch Electrical ^ Battery Junction Box (BJB) Fuse 7 (15A) ^ Central Junction Box (CJB) Fuse 4 (5A) ^ Damaged wiring harness ^ Loose or corroded connections ^ Damaged parking lamp relay ^ Damaged parking, rear or license lamp 3. If the concern is not visually evident, determine the symptom and proceed to Symptom Chart. See: Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11543 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11544 Tail Lamp: Pinpoint Tests Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11545 R1 - R2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11546 S1 - S2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11547 S3 - S4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11548 T1 - T2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11549 U1 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11550 U2 - U3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11551 73 Digital Multimeter Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Locations > Component Locations Trailer Lamps: Component Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Locations > Component Locations > Page 11556 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Locations > Component Locations > Page 11557 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Locations > Component Locations > Page 11558 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Locations > Component Locations > Page 11559 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Locations > Component Locations > Page 11560 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Locations > Component Locations > Page 11561 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Locations > Component Locations > Page 11562 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Locations > Component Locations > Page 11563 Trailer Lamps: Connector Locations C100-C115 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Locations > Component Locations > Page 11564 C116-C141 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Locations > Component Locations > Page 11565 C142-C172 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Locations > Component Locations > Page 11566 C174-C199 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Locations > Component Locations > Page 11567 C200-C227 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Locations > Component Locations > Page 11568 C228-C259 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Locations > Component Locations > Page 11569 C260-C406 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Locations > Component Locations > Page 11570 C407-C510 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Locations > Component Locations > Page 11571 C511-C1022 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Locations > Component Locations > Page 11572 G100-G400 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Locations > Component Locations > Page 11573 Trailer Lamps: Splice Locations S100 ............................................................................................ Engine control sensor harness, in Take Out (T/O) to Powertrain Control Module (PCM) S101 .................................................................................................................................................... ........... Engine control sensor harness, in T/O to PCM S102 ...................................................................................................................................... Engine control sensor harness, near T/O to starter motor relay S104 ............................................................................................................................................ Engine control sensor harness, near T/O to right headlamp S105 ....................................................................................................................................... Engine control sensor harness, in T/O to battery junction box S106 ........................................................................................................................................................... Engine control sensor harness, near T/O to G104 S108 ....................................................................................................................................... Engine control sensor harness, in T/O to battery junction box S109 ....................................................................................................................................................... Engine control sensor harness, near T/O to C150M S112 .................................................................................................................................... Engine control sensor harness, near T/O to battery junction box S113 .................................................................................................................................... Engine control sensor harness, near T/O to battery junction box S114 ............................................................................................................................................. Engine control sensor harness, near T/O to left headlamp S115 ....................................................................................................................................................... Engine control sensor harness, near T/O to C150M S116 ....................................................................................................................................................... Engine control sensor harness, near T/O to C160M S117 (4.2L) ........................................................................................................................................ Fuel charge harness, near T/O to idle air control valve S117 (4.6L, 5.4L) ...................................................................................................................................................... Fuel charge harness, near T/O to C120 S118 ......................................................................................................................................... Fuel charge harness, near T/O to radio noise capacitor C114 S119 ......................................................................................................................................... Fuel charge harness, near T/O to radio noise capacitor C115 S120 .......................................................................................................................................................... Engine control sensor harness, In T/O to C16OM S125 ............................................................................................................................... Heater blower motor feed harness, in T/O to blower motor resistor S126 ............................................................................................................. Engine control sensor harness, near T/O to A/C clutch cycling pressure switch S127 .............................................................................................................................. Engine control sensor harness, near T/O to windshield wiper motor S129 (4.2L) ................................................................................................................................... Fuel charge harness, between takeout for C126 and C123 S129 (4.6L, 5.4L) ....................................................................................................................................... Fuel charge harness, near T/O to coil on plug #3 S130 .......................................................................................................................................................... Engine control sensor harness, in T/O to C12OM S131 (4.2L)....................................................................................................... Fuel charge harness, near T/O to intake manifold runner control monitor #1 S131 (4.6L, 5.4L) ....................................................................................................................................... Fuel charge harness, near T/O to coil on plug #7 S135 (4.2L)................................................................................................................................................. Fuel charge harness, near T/O to fuel injector #4 S135 (4.6L, 5.4L)........................................................................................................................................ Fuel charge harness, near T/O to fuel injector #8 S136 (4.2L) ................................................................................................................................................ Fuel charge harness, near T/O to fuel injector #2 S136 (4.6L)........................................................................................................................................ Fuel charge harness, near T/O to C131 fuel injector #7 S136 (5.4L).................................................................................................................................................. Fuel charge harness, near T/O to coil on plug #4 S137 ...................................................................................................................................... Engine control sensor harness, near T/O to starter motor relay S138 ........................................................................ ....................................................................................... Engine control sensor harness, in T/O to C139 S139 ........................................................................................................................................................... Engine control sensor harness, in T/O to C158M S140 ................................................................................................................................. Reversing lamp switch to rear lamp feed harness, in T/O to C172 S141 ................................................................................................................................. Reversing lamp switch to rear lamp feed harness, in T/O to C172 S142 ...................................................................................................................................... Engine control sensor harness, near T/O to starter motor relay S143 .............................................................................................................................. Engine control sensor harness, near T/O to windshield wiper motor S145 ................................................................. .............................................................................................. Engine control sensor harness, in T/O to horns S146 ........................................................................................................................................................... Engine control sensor harness, near T/O to C159 S147 ................................................................................................................................................... Engine control sensor harness, in T/O to left fog lamp S148 ....................................................................................................................................................... Engine control sensor harness, near T/O to C148M S149 ........................................................................................................................................................... Engine control sensor harness, in T/O to C148M S150 ...................................................................... ......................................................................................... Engine control sensor harness, in T/O to C160 S153 ........................................................................................................................................... .............................. Fuel charge harness, near T/O to C120F S154 ................................................... ...................................................................................................................... Fuel charge harness, near T/O to C119F S155 ............................................................................................................................................ Engine control sensor harness, near T/O to in-line C158M S156 .............................................................................................................................................. Engine control sensor harness, near T/O to in-line C196F S157 .............................................................................................................................................. Engine control sensor harness, near T/O to in-line C196F S159 ........................................................................................................................ Engine control sensor harness, in T/O to C165 windshield wiper motor S160 ............................................................................................................................................ Engine control sensor harness, near T/O to in-line C158M S161 ........................................................................................................................................................... Fuel charge harness, near T/O to fuel injector #3 S162 ........................................................................................................................................................... Fuel charge harness, near T/O to fuel injector #7 S163 ............................................................................................................. Engine control sensor harness, near T/O to A/C clutch cycling pressure switch S170 ................................................................................ Engine control sensor harness, near T/O to 4 Wheel Anti-Lock Brake System (4WABS) module S198 ...................................................................................................................................... Engine control sensor harness, near T/O to starter motor relay S199 ........................................................................ ................................................................................................... Fuel charge harness, near T/O to C120 S200 ........................................................................................................................................... .......................................... Main harness, near T/O to C210 S201 .................................................................................................................... Main harness, near T/O to rear Anti-Lock Brake System (RABS) module S202 ........................................................................................................................................................ Main harness, in T/O to blower/flasher relay block S203 .................................................................... .............................................................................................. Main harness, near T/O to passenger air bag S204 ........................................................................................................................................ ......................... Main harness, near T/O to instrument cluster S205 .................................................. ..................................................................................................................... Main harness, near T/O to RABS module Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Locations > Component Locations > Page 11574 S206 .................................................................................................................................................... ..................................... Main harness, in T/O to C224 S207 .............................................................................................................................................................. Main harness, near T/O to central junction box S208 ......................................................................... ............................................................................................................ Main harness, near T/O to G202 S209 .......................................................................................................................................... ........................................... Main harness, near T/O to G202 S210 ........................................................................................................................................................... Radio speaker jumper harness, near T/O to radio S211 ..................................................................... ............................................................................................ Main harness, near T/O to instrument cluster S212 ......................................................................................................................................... ............................... Main harness, near T/O to in-line C253F S213 ........................................................................................................................................................... Main harness, in T/O to transfer case shift relays S214 ...................................................................... .................................................................................................. Main harness, near T/O to in-line C253F S215 ........................................................................................................................................ .................................. Main harness, in T/O to ignition switch S216 ............................................................................................................................................... Body main harness, near T/O to C254 park brake switch S217 ................................................................... ....................................................................................................... Main harness, in T/O to RABS module S218 ....................................................................................................................................... .............................................. Main harness, near T/O to C242 S219 ................................................. ...................................................................................................................... Main harness, near T/O to RABS module S220 ......................................................................................................................................................... Body main harness, near T/O to park brake switch S221 ................................................................... .................................................................................................................. Main harness, near T/O to C243 S222 ........................................................................................................................................... ...................... Main harness, near T/O to instrument cluster S223 ..................................................... ............................................................................................................ Main harness, near T/O to instrument cluster S224 ....................................................................................................................... .......................................... Main harness, near T/O to instrument cluster S225 ................................. ................................................................................................................................ Main harness, near T/O to instrument cluster S227 ......................................................................................................................................... Main harness, in T/O to Clutch Pedal Position (CPP) switch S228 .............................................................. .................................................................................................... Main harness, in T/O to central junction box S229 ................................................................................................................................ ................................. Main harness, near T/O to instrument cluster S231 .......................................... ....................................................................................................................... Main harness, near T/O to instrument cluster S232 ................................................................................................................... .............................................. Main harness, near T/O to instrument cluster S233 ............................. ............................................................................................................................................................ Main harness, in T/O to C225 S234 ........................................................................................................... Body main harness, near T/O to Remote Anti-Theft Personality (RAP) module S235 ........................................................................ ........................................................................................ Body main harness, near T/O to RAP module S236 ....................................................................................................................................... .......................... Main harness, near T/O to instrument cluster S237 ................................................. .................................................................................................................................... Main harness, near T/O to C243 S238 ................................................................................................................................ Main harness, in T/O to C239 Generic Electronic Module (GEM) S239 .................................................................................................................................................... ..................... Body main harness, near T/O to C206M S240 .............................................................................................................................................................. Main harness, near T/O to ashtray illumination S241 .......................................................................... ........................................................................................ Main harness, near T/O to passenger air bag S242 ............................................................................................................................................. .............................. Main harness, near T/O to CPP switch S243 ....................................................... .................................................................................................................. Body main harness, near T/O to C206M S244 ............................................................................................................................. ...................................... Main harness, near T/O to main light switch S245 ....................................... ........................................................................................................................... Main harness, near T/O to passenger air bag S246 ........................................................................................................... ............................................................. Main harness, near T/O to in-line C159F S247 ..................... ................................................................................................................................................... Main harness, near T/O to in-line C159F S248 ......................................................................................................................................................... Body main harness, near T/O to park brake switch S251 ................................................................... ...................................................................................................... Body main harness, near T/O to C206M S252 ........................................................................................................................................ ............................................... Main harness, in T/O to C265F S253 .................................................. ................................................................................................................... Radio amplifier harness, near T/O to C265 S254 .......................................................................................................................................................... Radio amplifier harness, near T/O to CD changer S265 ..................................................................... ................................................................................................................ Main harness, near T/O to C242 S268 ........................................................................................................................................... ................................ Main harness, near T/O to C240 GEM S289 ...................................................... .................................................................................................................. Main harness, near T/O to in-line C270F S291 .............................................................................................................................. ......................................... Main harness, near T/O to RABS module S294 .................................................................................................................................................... Main harness, near T/O to RABS data link connector S297 ........................................................................ ......................................................................................... Main harness, near T/O to instrument cluster S300 .................................................................................................................................. Seat belt retractor switch right harness, near T/O to interior lamp S301 ................................................................................................................................. Fuel tank sender harness, near T/O to fuel tank solenoid valve #2 S302 ................................................................................................................................. Fuel tank sender harness, near T/O to fuel tank solenoid valve #2 S303 ....................................................................... ............................................................................................ Fuel tank sender harness, near T/O to C316 S304 ................................................................................................................................... Seat belt retractor switch harness, near T/O to right rear speaker S400 ...................................................................................................................................................... Rear lamp harness, near T/O to fuel pump assembly S401 .......................................................................................................................................................... Rear lamp connector harness, near T/O to C403F S403 .......................................................................................................................................................... Rear lamp connector harness, near T/O to C403F S405 .................................................................................................................................... In rear lamp harness, near T/O to C404 left stop/park/turn lamp S409 ......................................................................................................................................................... Rear lamp harness, near T/O to fuel pump module S410 ......................................................................................................................................................... Rear lamp harness, near T/O to fuel pump module S411 ........................................................................................................................................... Rear lamp harness, in T/O to C911 high mounted stoplamp S500 ......................................................................................................................................... Body main harness, near T/O to left power door lock switch S501 .................................................................................................................................................. Body main harness, near T/O to left door lock actuator Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Locations > Component Locations > Page 11575 S503 ............................................................................................................................................. Body main harness, near T/O to left power window motor S600 .......................................................................................................................................... Body main harness, near T/O to right power window switch S911 ......................................................................................................................................... Rear high mounted lamp harness, near T/O to in-line C416F S1001 .................................................................. ........................................................................................................... Battery harness, near T/O to battery S1002 ...................................................................................................................................... ....................................... Battery harness, near T/O to battery S1003 .................................................................................................................................. Engine control sensor harness, near T/O to battery junction box Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > C232 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > C232 > Page 11578 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > C232 > Page 11579 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > C232 > Page 11580 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > C232 > Page 11581 Trailer Lamps: Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > C232 > Page 11582 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > C232 > Page 11583 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > C232 > Page 11584 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > C232 > Page 11585 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Diagrams > Page 11586 Trailer Lamps: Description and Operation Vehicles equipped with the trailer towing package have the additions to support the trailer wiring: ^ A set of relays in the engine compartment and connector on the rear lamp wiring, located in the rear bumper area. ^ Trailer feed wiring is supplied with the vehicle and installed at the time of pre-delivery. ^ Vehicles are equipped with a wiring feed, located under the instrument panel, for a trailer brake control unit. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis Trailer Lamps: Flow of Diagnosis 1. Verify the customer concern by operating the trailer towing package. 2. Visually inspect for the following obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Battery Junction Box (BJB) Fuse 5 (20A) ^ BJB Fuse 19 (10A) ^ BJB Fuse 20 (10A) ^ BJB Fuse 101 (30A) ^ BJB Fuse 108 (30A) ^ Central Junction Box (CJB) Fuse 23 (10A) ^ CJB Fuse 13 (10A) ^ Corroded/loose connector(s) ^ Loose/broken wire(s) ^ Failed bulb(s) 3. If the concern is not visually evident, determine the symptom and proceed to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11589 Trailer Lamps: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the trailer towing package. 2. Visually inspect for the following obvious signs of electrical damage. VISUAL INSPECTION CHART Electrical ^ Battery Junction Box (BJB) Fuse 5 (20A) ^ BJB Fuse 19 (10A) ^ BJB Fuse 20 (10A) ^ BJB Fuse 101 (30A) ^ BJB Fuse 108 (30A) ^ Central Junction Box (CJB) Fuse 23 (10A) ^ CJB Fuse 13 (10A) ^ Corroded/loose connector(s) ^ Loose/broken wire(s) ^ Failed bulb(s) 3. If the concern is not visually evident, determine the symptom and proceed to the Symptom Chart. See: Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11590 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11591 Trailer Lamps: Pinpoint Tests Icons Used With Pinpoint Tests Pinpoint Test Step Icons Chart In diagnosis and testing, you will see that a number of icons are used in the pinpoint test steps. The icons will assist in diagnosing the vehicle concern in a timely manner. The icons that are used are shown in the Pinpoint Test Step Icons chart. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11592 AB1 - AB2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11593 AC1 - AC2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11594 AC3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11595 AD1 - AD2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11596 AD3 AE Trailer Parking Lamps Inop Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11597 AE1 - AE2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11598 AE3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11599 AE4 - AE5 AF Trailer Lamp Are Inop-Trailer Reversing Lamps Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11600 AF1 - AF2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11601 AF3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11602 AF4 - AF5 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11603 AG1 - AG2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11604 AG3 - AG4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11605 AH1 - AH2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11606 AH3 - AH5 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11607 73 Digital Multimeter Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Regular Production Option Relay Block Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Regular Production Option Relay Block > Page 11612 Trailer Lighting Relay: Locations Trailer Running Lamps Relay Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Regular Production Option Relay Block > Page 11613 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Regular Production Option Relay Block > Page 11614 Trailer Lighting Relay: Locations Trailer Tow Battery Charge Relay Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Regular Production Option Relay Block > Page 11615 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Regular Production Option Relay Block > Page 11616 Trailer Lighting Relay: Locations Trailer Tow Reversing Lamp Relay Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Regular Production Option Relay Block > Page 11617 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 11618 Trailer Lighting Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations > Page 11619 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 00-9-6 > May > 00 > Windshield Wipers - Operate While Switch is OFF Combination Switch: Customer Interest Windshield Wipers - Operate While Switch is OFF Article No. 00-9-6 DATE 5/1/00 TITLE WINDSHIELD WIPERS - FRONT WIPERS OPERATE WHILE SWITCH IS IN "OFF" POSITION FORD: 1999 TAURUS 1999-2000 MUSTANG, EXPLORER, F-150, F-250 LD, RANGER, WINDSTAR 2000 EXCURSION MERCURY: 1999 SABLE 1999-2000 MOUNTAINEER This TSB is being republished in its entirety to revise the vehicles affected and to update the Service Procedure. This TSB applies to the following vehicles only: Explorer, Mountaineer and Ranger 4X2 Without Power Windows built through 9/12/1999 Excursion built through 8/25/1999 F-150/250, Mustang, Windstar, Taurus/Sable built through 8/16/1999 ISSUE The front windshield wipers may operate while the multifunction switch is in the OFF position on some vehicles. This may be caused by a resistance drift in the multifunction switch or a partially plugged-in connector. ACTION If the uncommanded wiper operation condition is present and all wiper related connectors are fully seated, install a revised multifunction switch. Refer to the following Service Procedure and the Multifunction Switch Application Chart for the applicable switch. SERVICE PROCEDURE NOTE: DO NOT ATTEMPT TO REPAIR THE VEHICLE BY REPLACING THE GENERIC ELECTRONIC MODULE (GEM) OR THE WIPER CONTROL MODULE. NOTE: MAKE SURE THAT ALL CONNECTIONS ARE FULLY SEATED TO THE GEM, CENTER INSTRUMENT PANEL COMPONENTS, FRONT WIPER MOTOR AND MULTIFUNCTION SWITCH DURING INSTALLATION. CHECK THE MULTIFUNCTION SWITCH CONNECTION CLOSELY FOR LOOSE CONNECTIONS, TERMINALS, AND TERMINAL PUSH OUTS. DO NOT ATTEMPT A CONTINUITY CHECK OR PROBE THE CIRCUITS OF THE WIRE HARNESS. If non-wiper related symptoms are present, perform diagnostics per the appropriate Workshop Manual. If the uncommanded wiper operation condition is present and no other symptoms apply to the vehicle being serviced, install a revised multifunction switch. Refer to the Multifunction Switch Application Chart for the applicable switch. NOTE: MAKE SURE THAT ALL CONNECTIONS ARE FULLY SEATED DURING INSTALLATION. DO NOT ATTEMPT TO REPAIR THE VEHICLE BY REPLACING THE GEM OR THE WIPER CONTROL MODULE. Using Worldwide Diagnostic System (WDS), New Generation Star (NGS) Jester or Service Bay Diagnostic System (SBDS), run GEM or CTM. Retrieve and clear continuous Diagnostic Trouble Codes (DTCs) and run On-Demand Self-Test to make sure that no valid DTCs are set. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 00-9-6 > May > 00 > Windshield Wipers - Operate While Switch is OFF > Page 11629 MALFUNCTION SWITCH APPLICATION PARTS SUPERSEDES: 99-24-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 202000, 203000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 00-9-6 > May > 00 > Windshield Wipers Operate While Switch is OFF Combination Switch: All Technical Service Bulletins Windshield Wipers - Operate While Switch is OFF Article No. 00-9-6 DATE 5/1/00 TITLE WINDSHIELD WIPERS - FRONT WIPERS OPERATE WHILE SWITCH IS IN "OFF" POSITION FORD: 1999 TAURUS 1999-2000 MUSTANG, EXPLORER, F-150, F-250 LD, RANGER, WINDSTAR 2000 EXCURSION MERCURY: 1999 SABLE 1999-2000 MOUNTAINEER This TSB is being republished in its entirety to revise the vehicles affected and to update the Service Procedure. This TSB applies to the following vehicles only: Explorer, Mountaineer and Ranger 4X2 Without Power Windows built through 9/12/1999 Excursion built through 8/25/1999 F-150/250, Mustang, Windstar, Taurus/Sable built through 8/16/1999 ISSUE The front windshield wipers may operate while the multifunction switch is in the OFF position on some vehicles. This may be caused by a resistance drift in the multifunction switch or a partially plugged-in connector. ACTION If the uncommanded wiper operation condition is present and all wiper related connectors are fully seated, install a revised multifunction switch. Refer to the following Service Procedure and the Multifunction Switch Application Chart for the applicable switch. SERVICE PROCEDURE NOTE: DO NOT ATTEMPT TO REPAIR THE VEHICLE BY REPLACING THE GENERIC ELECTRONIC MODULE (GEM) OR THE WIPER CONTROL MODULE. NOTE: MAKE SURE THAT ALL CONNECTIONS ARE FULLY SEATED TO THE GEM, CENTER INSTRUMENT PANEL COMPONENTS, FRONT WIPER MOTOR AND MULTIFUNCTION SWITCH DURING INSTALLATION. CHECK THE MULTIFUNCTION SWITCH CONNECTION CLOSELY FOR LOOSE CONNECTIONS, TERMINALS, AND TERMINAL PUSH OUTS. DO NOT ATTEMPT A CONTINUITY CHECK OR PROBE THE CIRCUITS OF THE WIRE HARNESS. If non-wiper related symptoms are present, perform diagnostics per the appropriate Workshop Manual. If the uncommanded wiper operation condition is present and no other symptoms apply to the vehicle being serviced, install a revised multifunction switch. Refer to the Multifunction Switch Application Chart for the applicable switch. NOTE: MAKE SURE THAT ALL CONNECTIONS ARE FULLY SEATED DURING INSTALLATION. DO NOT ATTEMPT TO REPAIR THE VEHICLE BY REPLACING THE GEM OR THE WIPER CONTROL MODULE. Using Worldwide Diagnostic System (WDS), New Generation Star (NGS) Jester or Service Bay Diagnostic System (SBDS), run GEM or CTM. Retrieve and clear continuous Diagnostic Trouble Codes (DTCs) and run On-Demand Self-Test to make sure that no valid DTCs are set. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 00-9-6 > May > 00 > Windshield Wipers Operate While Switch is OFF > Page 11635 MALFUNCTION SWITCH APPLICATION PARTS SUPERSEDES: 99-24-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 202000, 203000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Indicator > Component Information > Description and Operation Turn Signal Indicator: Description and Operation The right and left turn indicators will illuminate when the multifunction switch is in either turn signal position or hazard lamps position and sends a battery signal to the instrument cluster. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 11645 Turn Signal Switch: Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 11646 Turn Signal Switch: Description and Operation The integrated multifunction switch is mounted to the LH side of the steering column and controls the turn signal, headlamp dimmer/flash-to-pass, windshield wiper/washer and hazard warning. The ignition switch is mounted below the steering column and is activated using the ignition key and rotating the key lock cylinder on the steering column. If equipped with manual transmission, the key release lever prevents rotation of the ignition cylinder to LOCK or ACC positions unless the lever is depressed. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis Turn Signal Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11649 Turn Signal Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11650 Turn Signal Switch: Diagnostic Trouble Code Descriptions GEM/CTM Diagnostic Trouble Code (DTC) Index Part 1 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11651 Part 2 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11652 Part 3 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11653 Part 4 Of 4 GEM/CTM Active Command Index Part 1 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11654 Part 2 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11655 Turn Signal Switch: Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11656 Turn Signal Switch: Testing and Inspection Flow of Diagnosis 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Initial Inspection and Diagnostic Overview Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11657 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures GEM/CTM Diagnostic Trouble Code (DTC) Index Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11658 Part 1 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11659 Part 2 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11660 Part 3 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11661 Part 4 Of 4 GEM/CTM Active Command Index Part 1 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11662 Part 2 Of 2 Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11663 Component Tests and General Diagnostics Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11664 Schematic Pinout Values and Diagnostic Parameters Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11665 Part 1 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11666 Part 2 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11667 Part 3 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Page 11668 Turn Signal Switch: Service and Repair MULTIFUNCTION SWITCH Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1. Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2. Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder 3. Twist the tilt wheel handle and shank and remove. 4. NOTE: Move gear selector to lowest position to access steering column opening cover. Release the four clips and remove the steering column opening cover. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Page 11669 5. Remove the upper and lower steering column shrouds. 1. Remove the three screws. 2. Remove the lower steering column shroud. 3. Remove the upper steering column shroud. 6. Remove the mult1 function switch. 1. Remove the two screws. 2. Disconnect the electrical connectors. 3. Remove the mult1 function switch. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Testing and Inspection > Page 11670 Special Tools Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Revised Article No. 01-21-6 10/29/01 ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE MERCURY HOOD LAMP SWITCH FORD: 1987-1995 TAURUS 1988-1991 CROWN VICTORIA 1989 THUNDERBIRD 1989-1996 MUSTANG 1994-1996 THUNDERBIRD 1990 BRONCO II 1990-1996 RANGER 1991-1996 BRONCO 1994-2001 EXPLORER 1997-2001 F-150 2000-2001 EXCURSION 2002 EXPEDITION LINCOLN: 1989-1994 CONTINENTAL 1990-1992 MARK VII 1990-1996 TOWN CAR 1993-1995 MARK VIII 2002 NAVIGATOR MERCURY: 1987-1995 SABLE 1988-1991 GRAND MARQUIS 1989 COUGAR 1994-1996 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is to provide information on replacement hood lamp switches. The 27 degree Mercury style hood switches will no longer be available. Replacement 27 degree Mechanical switches will be available as a service replacement. ACTION For vehicles requiring hood lamp switch replacement, replace the 27 degree Mercury switch with new 27 degree Mechanical switch. Replace hood lamp switch per the appropriate model year Workshop Manual as needed. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised > Page 11676 OASIS CODES: 201000, 201200 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations Power Window Relay: Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Page 11682 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Page 11683 Power Window Relay: Description and Operation The GEM controls manual down and OTD window movement with the one touch down relay. The relay is activated by applying ground directly to one side of the down window relay coil, and is deactivated by removing the ground signal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Page 11684 Power Window Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations > Page 11685 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Driver's Power Window Switch Power Window Switch: Diagrams Driver's Power Window Switch Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Driver's Power Window Switch > Page 11691 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 11692 Power Window Switch: Description and Operation The window regulator control switch: - Is located on each front door trim panel. - May be used to raise or lower both driver side and passenger side windows from the master control on the driver side, or the passenger side window from the passenger side switch. - Includes a "double detent" feature. - Can manually lower the driver side window when the master control is depressed half way (first detent). - Will completely lower the driver side window when the master control is fully depressed (second detent) and then released. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Left Power Window Switch: Testing and Inspection Left Component Testing Procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Left > Page 11695 Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Left > Page 11696 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Left > Page 11697 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Left > Page 11698 Power Window Switch: Testing and Inspection Right Window Switch Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Left > Page 11699 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Testing and Inspection > Page 11700 Power Window Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the window regulator switch plate. 1 Pry up the window regulator switch plate. 2 Disconnect the electrical connectors. 3. Remove the window regulator control switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery ground cable is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Specifications Power Window Motor: Specifications Power Window Motor Bolts .......................................................................................................................................................... 5.6-9.1 Nm (50-81 in lbs) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Specifications > Page 11705 Power Window Motor: Service and Repair REMOVAL 1. Raise the front door window glass to the full up position. 2. Remove the front door trim panel. 3. Peel back the front door watershield. 4. To access the power window motor bolts, use a 3/4-inch hole saw with a 1/4-inch pilot to drill two holes at the existing drill dimples on the door. NOTE: Make sure the electrical connector is not in the way before drilling. 5. Remove the power window motor. 1 Remove the bolts. 2 Disconnect the electrical connector. 3 Remove the power window motor. NOTE: Prior to motor removal, make sure the regulator arms are in a fixed position to prevent counterbalance spring unwind. INSTALLATION 1. To install, reverse the removal procedure. - Cycle the door glass to make sure the gears engage. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations Power Window Relay: Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations > Page 11709 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations > Page 11710 Power Window Relay: Description and Operation The GEM controls manual down and OTD window movement with the one touch down relay. The relay is activated by applying ground directly to one side of the down window relay coil, and is deactivated by removing the ground signal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations > Page 11711 Power Window Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations > Page 11712 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Driver's Power Window Switch Power Window Switch: Diagrams Driver's Power Window Switch Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Driver's Power Window Switch > Page 11717 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Page 11718 Power Window Switch: Description and Operation The window regulator control switch: - Is located on each front door trim panel. - May be used to raise or lower both driver side and passenger side windows from the master control on the driver side, or the passenger side window from the passenger side switch. - Includes a "double detent" feature. - Can manually lower the driver side window when the master control is depressed half way (first detent). - Will completely lower the driver side window when the master control is fully depressed (second detent) and then released. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Left Power Window Switch: Testing and Inspection Left Component Testing Procedure Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Left > Page 11721 Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Left > Page 11722 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Left > Page 11723 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Left > Page 11724 Power Window Switch: Testing and Inspection Right Window Switch Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Left > Page 11725 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing and Inspection > Page 11726 Power Window Switch: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Remove the window regulator switch plate. 1 Pry up the window regulator switch plate. 2 Disconnect the electrical connectors. 3. Remove the window regulator control switch. INSTALLATION 1. To install, reverse the removal procedure. NOTE: When the battery ground cable is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Frame > Component Information > Technical Service Bulletins > Customer Interest for Window Frame: > 01-1-11 > Jan > 01 > Sliding Rear Window - Water Leaks to Interior Window Frame: Customer Interest Sliding Rear Window - Water Leaks to Interior Article No. 01-1-11 01/22/01 WATER LEAK - SLIDING REAR WINDOW - VEHICLES BUILT THROUGH 4/1999 FORD: 1997-1999 F-150, F-250 LD ISSUE Some vehicles may exhibit a water leak around the rear (sliding) window. This may be caused by a crack in the plastic frame around the window and/or deterioration of the butyl seal between plastic frame and cab. ACTION Remove the rear sliding window module and apply a gusset seal. Reinstall the same window module. The gusset seal should reduce the possibility of leaks. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE: PREVIOUSLY, WHEN A SLIDING GLASS REAR WINDOW ON AN F-150/F-250 LD WAS FOUND TO BE LEAKING, THE SERVICE PROCEDURE WAS TO REPLACE THE LEAKING WINDOW MODULE WITH A NEW SLIDING WINDOW MODULE. THE NEW PROCEDURE DETAILED IN THIS TSB DESCRIBES HOW TO USE THE SERVICE FIX SEAL TO REPAIR AND REUSE A REAR WINDOW MODULE. LEAK CHECK THE REAR WINDOW 1. From inside the cab, check to make sure sliding pane is latched closed and area around window is initially dry. 2. Spray water at moderate pressure into margin between window module and halo moulding around window module. 3. From inside cab, check for water dripping down inside window. In particular, look for drips coming down the side (fixed) panes of the window. 4. If water is coming through the seals that seal the sliding pane itself (a less common leak path), the gusset seal will not correct the leak and the window module will need to be replaced. APPLY REAR WINDOW GUSSET SEAL 1. If rear window is found to be leaking, remove it according to Section 501-11 of the appropriate year F-150/F-250 LD Workshop Manual. Take care when removing it to not damage it or the cab sheet metal around it. Try to minimize bending of the window module. NOTE: IF THE VEHICLE WAS BUILT PRIOR TO 2/1998, THE HALO MOULDING (STILL ATTACHED TO THE CAB) THAT NORMALLY FRAMES THE REAR WINDOW MODULE HAS TABS ON IT THAT NEED TO BE REMOVED. THESE TABS (NOT PRESENT ON VEHICLES BUILT AFTER 2/1998) HANG DOWN FROM THE UNDERSIDE OF THE TOP OF THE HALO MOULDING. THEY ENGAGE SLOTS IN THE BACK OF THE TOP OF THE WINDOW MODULE AND MUST BE A REMOVED PRIOR TO REINSTALLATION OF THE WINDOW MODULE. 2. Check if the window module is repairable. a. Look for vertical cracks in the plastic division bars that separate the fixed from the sliding panes. b. Look for separation of the side panes from the plastic frame. c. If either of these conditions are present (usually caused by excessive bending during removal), the module can't be repaired and needs to be replaced with a new module. 3. If the window module is repairable, obtain the Gusset Seal (XL3Z-1542086-AA) and the Standard Butyl Sealing Cord (E69Z-19562-A). 4. Thoroughly clean sheet metal opening in cab of residue from previous butyl seal. Butyl can be used to "blot" butyl off of the sheet metal. If the surface is not properly cleaned of all residue, the window may leak after it is reinstalled. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Frame > Component Information > Technical Service Bulletins > Customer Interest for Window Frame: > 01-1-11 > Jan > 01 > Sliding Rear Window - Water Leaks to Interior > Page 11735 5. Clean the back of the window module of the previous butyl seal using the methods described. Additionally, clean the top of the window module. Pay particular attention to the lip of the glass that extends above the frame. This lip of glass (the side on top of the module) must be clean for the gusset seal to adhere properly. 6. Place short (25 mm/1 ") sections of standard butyl sealing cord behind the gaps between the side panes of glass and the division bars (Figure 4). Make sure the butyl seats against the plastic frame at the bottom of the gap. If this is not done, the gaps provide a leak path for water to get by the gusset seal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Frame > Component Information > Technical Service Bulletins > Customer Interest for Window Frame: > 01-1-11 > Jan > 01 > Sliding Rear Window - Water Leaks to Interior > Page 11736 7. Leaving the release tape in place, unpack gusset seal and refer to remaining Figures 1-3 to understand how the seal will be applied to the window module. 8. Notice that a standard butyl sealing cord is applied to the window before the fix is applied (Figure 2). 9. Leaving the release tape on, apply a standard butyl sealing cord to the back of the window module taking care to lay the butyl in the "track" moulded into the plastic window frame. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Frame > Component Information > Technical Service Bulletins > Customer Interest for Window Frame: > 01-1-11 > Jan > 01 > Sliding Rear Window - Water Leaks to Interior > Page 11737 10. Place window (back side up) on a clean, stable surface with the top edge of the window module facing you. The gusset seal will be applied to the top edge (Figure 3). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Frame > Component Information > Technical Service Bulletins > Customer Interest for Window Frame: > 01-1-11 > Jan > 01 > Sliding Rear Window - Water Leaks to Interior > Page 11738 11. Check (Figure 1) and find the pre-attached butyl seal that is to be applied to the back edge of the glass. This edge of the gusset seal is thick, rather than flat. Remove the release tape from this butyl seal only. 12. Once installed the gusset seal should extend from one stud on the sloping side of the window module to the opposite stud on the opposite sloping side of the window module (Figures 2 and 3). In the process, it should cover the entire top of the plastic frame behind the glass and down to just above the row of studs across the back of the module. 13. Starting at one side of the module, apply the butyl bead (exposed in Step 12) to the crevice between the back of the glass and the top of the module. It is important that the butyl seals to the glass in order for the gusset seal to not leak. Additionally, try to minimize the protrusion of the seal onto the visible side of the glass. It should be below the rounded edge of the glass. 14. Moving across the top of the module, apply the butyl bead on the edge of the gusset seal to the back of one fixed pane, the plastic lip above the sliding pane, and then across the back edge of the other fixed pane. Make sure that the butyl on the gusset seal seals to the two (2) small pieces of butyl applied in Step 6. 15. Remove the release tape from the standard seal applied in Step 9. Refer to Figure 2 to see how the gusset seal is applied to the standard butyl seal. Starting at one side, stick the back of the gusset seal to the standard butyl seal. At this point, the gusset seal should cover the entire top of the window module down to the row of studs. 16. Remove the release tape from the second butyl strip on the gusset seal. This will seal to the back of the cab. 17. Reinstall the window module according to Section 501-11 of the appropriate year F-150/F-250 LD Workshop Manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION/DESCRIPTION/TIME Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Frame > Component Information > Technical Service Bulletins > Customer Interest for Window Frame: > 01-1-11 > Jan > 01 > Sliding Rear Window - Water Leaks to Interior > Page 11739 DEALER CODING OASIS CODES: 102000,108000,110000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Frame: > 01-1-11 > Jan > 01 > Sliding Rear Window - Water Leaks to Interior Window Frame: All Technical Service Bulletins Sliding Rear Window - Water Leaks to Interior Article No. 01-1-11 01/22/01 WATER LEAK - SLIDING REAR WINDOW - VEHICLES BUILT THROUGH 4/1999 FORD: 1997-1999 F-150, F-250 LD ISSUE Some vehicles may exhibit a water leak around the rear (sliding) window. This may be caused by a crack in the plastic frame around the window and/or deterioration of the butyl seal between plastic frame and cab. ACTION Remove the rear sliding window module and apply a gusset seal. Reinstall the same window module. The gusset seal should reduce the possibility of leaks. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE: PREVIOUSLY, WHEN A SLIDING GLASS REAR WINDOW ON AN F-150/F-250 LD WAS FOUND TO BE LEAKING, THE SERVICE PROCEDURE WAS TO REPLACE THE LEAKING WINDOW MODULE WITH A NEW SLIDING WINDOW MODULE. THE NEW PROCEDURE DETAILED IN THIS TSB DESCRIBES HOW TO USE THE SERVICE FIX SEAL TO REPAIR AND REUSE A REAR WINDOW MODULE. LEAK CHECK THE REAR WINDOW 1. From inside the cab, check to make sure sliding pane is latched closed and area around window is initially dry. 2. Spray water at moderate pressure into margin between window module and halo moulding around window module. 3. From inside cab, check for water dripping down inside window. In particular, look for drips coming down the side (fixed) panes of the window. 4. If water is coming through the seals that seal the sliding pane itself (a less common leak path), the gusset seal will not correct the leak and the window module will need to be replaced. APPLY REAR WINDOW GUSSET SEAL 1. If rear window is found to be leaking, remove it according to Section 501-11 of the appropriate year F-150/F-250 LD Workshop Manual. Take care when removing it to not damage it or the cab sheet metal around it. Try to minimize bending of the window module. NOTE: IF THE VEHICLE WAS BUILT PRIOR TO 2/1998, THE HALO MOULDING (STILL ATTACHED TO THE CAB) THAT NORMALLY FRAMES THE REAR WINDOW MODULE HAS TABS ON IT THAT NEED TO BE REMOVED. THESE TABS (NOT PRESENT ON VEHICLES BUILT AFTER 2/1998) HANG DOWN FROM THE UNDERSIDE OF THE TOP OF THE HALO MOULDING. THEY ENGAGE SLOTS IN THE BACK OF THE TOP OF THE WINDOW MODULE AND MUST BE A REMOVED PRIOR TO REINSTALLATION OF THE WINDOW MODULE. 2. Check if the window module is repairable. a. Look for vertical cracks in the plastic division bars that separate the fixed from the sliding panes. b. Look for separation of the side panes from the plastic frame. c. If either of these conditions are present (usually caused by excessive bending during removal), the module can't be repaired and needs to be replaced with a new module. 3. If the window module is repairable, obtain the Gusset Seal (XL3Z-1542086-AA) and the Standard Butyl Sealing Cord (E69Z-19562-A). 4. Thoroughly clean sheet metal opening in cab of residue from previous butyl seal. Butyl can be used to "blot" butyl off of the sheet metal. If the surface is not properly cleaned of all residue, the window may leak after it is reinstalled. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Frame: > 01-1-11 > Jan > 01 > Sliding Rear Window - Water Leaks to Interior > Page 11745 5. Clean the back of the window module of the previous butyl seal using the methods described. Additionally, clean the top of the window module. Pay particular attention to the lip of the glass that extends above the frame. This lip of glass (the side on top of the module) must be clean for the gusset seal to adhere properly. 6. Place short (25 mm/1 ") sections of standard butyl sealing cord behind the gaps between the side panes of glass and the division bars (Figure 4). Make sure the butyl seats against the plastic frame at the bottom of the gap. If this is not done, the gaps provide a leak path for water to get by the gusset seal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Frame: > 01-1-11 > Jan > 01 > Sliding Rear Window - Water Leaks to Interior > Page 11746 7. Leaving the release tape in place, unpack gusset seal and refer to remaining Figures 1-3 to understand how the seal will be applied to the window module. 8. Notice that a standard butyl sealing cord is applied to the window before the fix is applied (Figure 2). 9. Leaving the release tape on, apply a standard butyl sealing cord to the back of the window module taking care to lay the butyl in the "track" moulded into the plastic window frame. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Frame: > 01-1-11 > Jan > 01 > Sliding Rear Window - Water Leaks to Interior > Page 11747 10. Place window (back side up) on a clean, stable surface with the top edge of the window module facing you. The gusset seal will be applied to the top edge (Figure 3). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Frame: > 01-1-11 > Jan > 01 > Sliding Rear Window - Water Leaks to Interior > Page 11748 11. Check (Figure 1) and find the pre-attached butyl seal that is to be applied to the back edge of the glass. This edge of the gusset seal is thick, rather than flat. Remove the release tape from this butyl seal only. 12. Once installed the gusset seal should extend from one stud on the sloping side of the window module to the opposite stud on the opposite sloping side of the window module (Figures 2 and 3). In the process, it should cover the entire top of the plastic frame behind the glass and down to just above the row of studs across the back of the module. 13. Starting at one side of the module, apply the butyl bead (exposed in Step 12) to the crevice between the back of the glass and the top of the module. It is important that the butyl seals to the glass in order for the gusset seal to not leak. Additionally, try to minimize the protrusion of the seal onto the visible side of the glass. It should be below the rounded edge of the glass. 14. Moving across the top of the module, apply the butyl bead on the edge of the gusset seal to the back of one fixed pane, the plastic lip above the sliding pane, and then across the back edge of the other fixed pane. Make sure that the butyl on the gusset seal seals to the two (2) small pieces of butyl applied in Step 6. 15. Remove the release tape from the standard seal applied in Step 9. Refer to Figure 2 to see how the gusset seal is applied to the standard butyl seal. Starting at one side, stick the back of the gusset seal to the standard butyl seal. At this point, the gusset seal should cover the entire top of the window module down to the row of studs. 16. Remove the release tape from the second butyl strip on the gusset seal. This will seal to the back of the cab. 17. Reinstall the window module according to Section 501-11 of the appropriate year F-150/F-250 LD Workshop Manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION/DESCRIPTION/TIME Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Frame > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Frame: > 01-1-11 > Jan > 01 > Sliding Rear Window - Water Leaks to Interior > Page 11749 DEALER CODING OASIS CODES: 102000,108000,110000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair Back Window Glass: Service and Repair REMOVAL 1. Remove the rear seat back. 1 Remove the bolts. 2 Lift up to remove the rear seat back. 2. Remove the safety belt guide bolt. 1 Lift the cover. 2 Remove the bolt. 3. Remove the roof side rear trim panel. 1 Remove the push pin. 2 Pry and release the clips. 3 Slide the roof side trim panel out of the retainers and remove the roof side trim panel. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Page 11754 4. Remove the coat hooks. 1 Remove the two screws. 2 Remove the two coat hooks. 5. Remove the dome lamp. 1 Carefully pry the lens out of the dome lamp. 2 Remove the dome lamp screws. 3 Remove the dome lamp. 6. Lower the back half of the roof trim panel. 7. Cut the foam butyl from around the back window glass. 8. Remove the back window glass. 1 Remove the 12 nuts. 2 Remove the back window glass. 9. Remove any remaining foam butyl from the window glass frame. INSTALLATION 1. Clean the back window glass with an alcohol-free cleaner. 2. Apply 8 mm foam butyl (part of EOAZ-19562-A), or equivalent meeting Ford specification WSB-M2G234-C to the back window glass. - Start at the bottom middle and work around. 3. Install the back window glass. 1 Position the back window glass. 2 Install the 12 nuts. 4. Position the roof trim panel. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Page 11755 5. Install the dome lamp. 1 Position the dome lamp. 2 Install the dome lamp screws. 3 Install the lens. 6. Install the coat hooks. 1 Position the two coat hooks. 2 Install the two screws. 7. Install the roof side rear trim panel. 1 Slide the roof side rear trim panel into retainers and position the roof side trim panel. 2 Install the clips. 3 Install the push pin. 8. Install the safety belt guide bolt. 1 Install the bolt. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Component Information > Service and Repair > Page 11756 2 Install the cover. 9. Install the rear seat back. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > Customer Interest for Front Door Window Glass: > 03-2-4 > Feb > 03 > Body Driver Side Window Binds When Operated Front Door Window Glass: Customer Interest Body - Driver Side Window Binds When Operated Article No. 03-2-4 02/03/03 ^ BODY - DRIVER SIDE WINDOW BINDS WHEN OPERATED ^ ELECTRICAL - DRIVER SIDE WINDOW BINDS WHEN OPERATED FORD: 1997-2002 F-150 ISSUE Some vehicles may exhibit a driver's side door glass that binds when operated. This may be caused by the inner door panel developing a crack where the rear window run attaches. When the window is operated, the run flexes and causes the glass to bind in the run. ACTION Install a Reinforcement Plate Kit (XL3Z-15211B06-AA) on the inner door panel. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove door trim panel per the appropriate model year Workshop Manual. 2. Remove the current rear window run attachment bolt and discard. 3. Hold reinforcement plate (included in kit) in position (Figure 1) and mark the area where it will mount. 4. Use sand paper to rough up the area where the outer edge of the plate will mount. 5. Apply TA-12 Structural Foam to the reinforcement plate. 6. Place reinforcement plate in position and install the new bolt and washer assembly (included with kit). Torque the bolt to 8.4-11.5 Lb-ft (11.4-15.6 N.m). 7. Using the five holes around the perimeter of the plate as a guide, drill 3/16 inch (4.76 mm) holes in the inner door panel and install five rivets (included with kit). 8. Apply heat gun at 120° F (49° C) for up to 20 minutes to cure the Structural Foam. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > Customer Interest for Front Door Window Glass: > 03-2-4 > Feb > 03 > Body Driver Side Window Binds When Operated > Page 11765 9. Re-install the door trim panel. 10. Verify proper operation. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 030204A Install Reinforcement Plate 1.1 Hrs. On The Inner Door Panel (Includes Time To Remove And Install Watershield): 1997-1998 F-150 030204B Install Reinforcement Plate 0.9 Hr. On The Inner Door Panel (Includes Time To Remove And Install Watershield): 1999-2002 F-150 DEALER CODING CONDITION BASIC PART NO. CODE 1520255 01 OASIS CODES: 102000, 111000 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 03-2-4 > Feb > 03 > Body - Driver Side Window Binds When Operated Front Door Window Glass: All Technical Service Bulletins Body - Driver Side Window Binds When Operated Article No. 03-2-4 02/03/03 ^ BODY - DRIVER SIDE WINDOW BINDS WHEN OPERATED ^ ELECTRICAL - DRIVER SIDE WINDOW BINDS WHEN OPERATED FORD: 1997-2002 F-150 ISSUE Some vehicles may exhibit a driver's side door glass that binds when operated. This may be caused by the inner door panel developing a crack where the rear window run attaches. When the window is operated, the run flexes and causes the glass to bind in the run. ACTION Install a Reinforcement Plate Kit (XL3Z-15211B06-AA) on the inner door panel. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove door trim panel per the appropriate model year Workshop Manual. 2. Remove the current rear window run attachment bolt and discard. 3. Hold reinforcement plate (included in kit) in position (Figure 1) and mark the area where it will mount. 4. Use sand paper to rough up the area where the outer edge of the plate will mount. 5. Apply TA-12 Structural Foam to the reinforcement plate. 6. Place reinforcement plate in position and install the new bolt and washer assembly (included with kit). Torque the bolt to 8.4-11.5 Lb-ft (11.4-15.6 N.m). 7. Using the five holes around the perimeter of the plate as a guide, drill 3/16 inch (4.76 mm) holes in the inner door panel and install five rivets (included with kit). 8. Apply heat gun at 120° F (49° C) for up to 20 minutes to cure the Structural Foam. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > 03-2-4 > Feb > 03 > Body - Driver Side Window Binds When Operated > Page 11771 9. Re-install the door trim panel. 10. Verify proper operation. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 030204A Install Reinforcement Plate 1.1 Hrs. On The Inner Door Panel (Includes Time To Remove And Install Watershield): 1997-1998 F-150 030204B Install Reinforcement Plate 0.9 Hr. On The Inner Door Panel (Includes Time To Remove And Install Watershield): 1999-2002 F-150 DEALER CODING CONDITION BASIC PART NO. CODE 1520255 01 OASIS CODES: 102000, 111000 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > Page 11772 Front Door Window Glass: By Symptom Technical Service Bulletin # 03-2-4 Date: 030203 Body - Driver Side Window Binds When Operated Article No. 03-2-4 02/03/03 ^ BODY - DRIVER SIDE WINDOW BINDS WHEN OPERATED ^ ELECTRICAL - DRIVER SIDE WINDOW BINDS WHEN OPERATED FORD: 1997-2002 F-150 ISSUE Some vehicles may exhibit a driver's side door glass that binds when operated. This may be caused by the inner door panel developing a crack where the rear window run attaches. When the window is operated, the run flexes and causes the glass to bind in the run. ACTION Install a Reinforcement Plate Kit (XL3Z-15211B06-AA) on the inner door panel. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove door trim panel per the appropriate model year Workshop Manual. 2. Remove the current rear window run attachment bolt and discard. 3. Hold reinforcement plate (included in kit) in position (Figure 1) and mark the area where it will mount. 4. Use sand paper to rough up the area where the outer edge of the plate will mount. 5. Apply TA-12 Structural Foam to the reinforcement plate. 6. Place reinforcement plate in position and install the new bolt and washer assembly (included with kit). Torque the bolt to 8.4-11.5 Lb-ft (11.4-15.6 N.m). 7. Using the five holes around the perimeter of the plate as a guide, drill 3/16 inch (4.76 mm) holes in the inner door panel and install five rivets Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > Page 11773 (included with kit). 8. Apply heat gun at 120° F (49° C) for up to 20 minutes to cure the Structural Foam. 9. Re-install the door trim panel. 10. Verify proper operation. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 030204A Install Reinforcement Plate 1.1 Hrs. On The Inner Door Panel (Includes Time To Remove And Install Watershield): 1997-1998 F-150 030204B Install Reinforcement Plate 0.9 Hr. On The Inner Door Panel (Includes Time To Remove And Install Watershield): 1999-2002 F-150 DEALER CODING CONDITION BASIC PART NO. CODE 1520255 01 OASIS CODES: 102000, 111000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > Page 11774 Disclaimer Technical Service Bulletin # 03-2-4 Date: 030203 Body - Driver Side Window Binds When Operated Article No. 03-2-4 02/03/03 ^ BODY - DRIVER SIDE WINDOW BINDS WHEN OPERATED ^ ELECTRICAL - DRIVER SIDE WINDOW BINDS WHEN OPERATED FORD: 1997-2002 F-150 ISSUE Some vehicles may exhibit a driver's side door glass that binds when operated. This may be caused by the inner door panel developing a crack where the rear window run attaches. When the window is operated, the run flexes and causes the glass to bind in the run. ACTION Install a Reinforcement Plate Kit (XL3Z-15211B06-AA) on the inner door panel. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove door trim panel per the appropriate model year Workshop Manual. 2. Remove the current rear window run attachment bolt and discard. 3. Hold reinforcement plate (included in kit) in position (Figure 1) and mark the area where it will mount. 4. Use sand paper to rough up the area where the outer edge of the plate will mount. 5. Apply TA-12 Structural Foam to the reinforcement plate. 6. Place reinforcement plate in position and install the new bolt and washer assembly (included with kit). Torque the bolt to 8.4-11.5 Lb-ft (11.4-15.6 N.m). 7. Using the five holes around the perimeter of the plate as a guide, drill 3/16 inch (4.76 mm) holes in the inner door panel and install five rivets (included with kit). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Window Glass: > Page 11775 8. Apply heat gun at 120° F (49° C) for up to 20 minutes to cure the Structural Foam. 9. Re-install the door trim panel. 10. Verify proper operation. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION DESCRIPTION TIME 030204A Install Reinforcement Plate 1.1 Hrs. On The Inner Door Panel (Includes Time To Remove And Install Watershield): 1997-1998 F-150 030204B Install Reinforcement Plate 0.9 Hr. On The Inner Door Panel (Includes Time To Remove And Install Watershield): 1999-2002 F-150 DEALER CODING CONDITION BASIC PART NO. CODE 1520255 01 OASIS CODES: 102000, 111000 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > Page 11776 Front Door Window Glass: Service and Repair REMOVAL 1. Remove the front door trim panel. 2. Peel back the front door watershield. 3. Lower the window glass to access the two window glass to regulator nuts. 4. Remove the inside glass weatherstrip. 5. Remove the rear glass channel bolt and lift the channel. 6. Loosen the window glass to regulator nuts. - Slide glass channel rearward until the rear glass to regulator nut lines up with the hole in the glass channel. 7. Remove the front door window glass. NOTE: Slide the glass through the outboard side of the door. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System Information > Technical Service Bulletins > Page 11777 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System Information > Service and Repair Rear Door Window Glass: Service and Repair REMOVAL NOTE: Hinged glass shown, fixed glass similar. 1. If equipped, remove the rear door window latch screws. 2. Remove the rear door window garnish. 3. Remove the rear door window glass. 1 Remove the nuts. 2 Remove the rear door window glass. 4. Cut the excess foam butyl from the window frame. 5. Pry the window frame from the door. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System Information > Service and Repair > Page 11781 6. Remove the excess foam butyl from the window opening. INSTALLATION 1. Apply 8 mm foam butyl (part of EOAZ-19562-A), or equivalent meeting Ford specification WSB-M2G234-C to the rear window frame. - Start at the bottom middle and work around the frame. NOTE: When applying foam butyl, leave a slight overlap at the bottom to allow for drainage. 2. Install the rear window frame and glass. 1 Position the rear window frame and glass. 2 Tighten the nuts to specification. NOTE: Loosely install all nuts before tightening. 3. Install the rear door window garnish. 4. If equipped, install the rear door window latch screws. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair Front Door Window Regulator: Service and Repair Heavy Duty Riverter Special Tool(s) REMOVAL 1. Remove the front door trim panel. 2. Peel back the front door watershield. 3. Lower the front door window glass to access the two window regulator nuts. 4. Remove the window glass nuts. 5. Support the front door window glass in the full up position. 6. If equipped, disconnect the power window electrical connector. 7. Remove the window regulator. 1 Remove the nuts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Page 11786 2 Drill out the rivets. 3 Remove the window regulator. INSTALLATION 1. To install, reverse the removal procedure. - Use Heavy Duty Riveter to install the new rivets. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Specifications Rear Door Window Regulator: Specifications Window Glass to Regulator Nuts .................................................................................................................................................... 10-14 Nm (7.4-10 ft lbs) Window Regulator Nuts ................................................................................ .................................................................................. 10-14 Nm (7.4-10 ft lbs) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Customer Interest: > 04-2-2 > Feb > 04 > Body - Sliding Back Glass Windnoise/Water Leaks Window Seal: Customer Interest Body - Sliding Back Glass Windnoise/Water Leaks Article No. 04-2-2 02/09/04 BODY - BACK GLASS - SLIDING BACK GLASS WINDNOISE/WATER LEAK - SEAL REPLACEMENT FORD: 1999-2003 F-150 ISSUE Some 1999-2003 F-150 vehicles may exhibit windnoise and/or a water leak from the back glass area. ACTION To service, order and install Service kit 3L3Z-1542052-AA. Refer, to the installation instructions included in the kit. It will also be necessary to obtain a tube of Motorcraft Instant Adhesive (TA-19) or equivalent for this repair. NOTE THE KIT APPLIES TO BOTH MANUAL AND POWER SLIDING REAR WINDOWS. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 040202A Install Backlight Sliding 0.6 Hr. Seals (Includes Time To Remove Rear Seat Back On S/Cabs Vehicles Or To Loosen Upper Portion Of Back Panel On Regular Cab And Super Crew Vehicles DEALER CODING CONDITION BASIC PART NO. CODE 15420A26 33 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Customer Interest: > 01-1-11 > Jan > 01 > Sliding Rear Window - Water Leaks to Interior Window Seal: Customer Interest Sliding Rear Window - Water Leaks to Interior Article No. 01-1-11 01/22/01 WATER LEAK - SLIDING REAR WINDOW - VEHICLES BUILT THROUGH 4/1999 FORD: 1997-1999 F-150, F-250 LD ISSUE Some vehicles may exhibit a water leak around the rear (sliding) window. This may be caused by a crack in the plastic frame around the window and/or deterioration of the butyl seal between plastic frame and cab. ACTION Remove the rear sliding window module and apply a gusset seal. Reinstall the same window module. The gusset seal should reduce the possibility of leaks. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE: PREVIOUSLY, WHEN A SLIDING GLASS REAR WINDOW ON AN F-150/F-250 LD WAS FOUND TO BE LEAKING, THE SERVICE PROCEDURE WAS TO REPLACE THE LEAKING WINDOW MODULE WITH A NEW SLIDING WINDOW MODULE. THE NEW PROCEDURE DETAILED IN THIS TSB DESCRIBES HOW TO USE THE SERVICE FIX SEAL TO REPAIR AND REUSE A REAR WINDOW MODULE. LEAK CHECK THE REAR WINDOW 1. From inside the cab, check to make sure sliding pane is latched closed and area around window is initially dry. 2. Spray water at moderate pressure into margin between window module and halo moulding around window module. 3. From inside cab, check for water dripping down inside window. In particular, look for drips coming down the side (fixed) panes of the window. 4. If water is coming through the seals that seal the sliding pane itself (a less common leak path), the gusset seal will not correct the leak and the window module will need to be replaced. APPLY REAR WINDOW GUSSET SEAL 1. If rear window is found to be leaking, remove it according to Section 501-11 of the appropriate year F-150/F-250 LD Workshop Manual. Take care when removing it to not damage it or the cab sheet metal around it. Try to minimize bending of the window module. NOTE: IF THE VEHICLE WAS BUILT PRIOR TO 2/1998, THE HALO MOULDING (STILL ATTACHED TO THE CAB) THAT NORMALLY FRAMES THE REAR WINDOW MODULE HAS TABS ON IT THAT NEED TO BE REMOVED. THESE TABS (NOT PRESENT ON VEHICLES BUILT AFTER 2/1998) HANG DOWN FROM THE UNDERSIDE OF THE TOP OF THE HALO MOULDING. THEY ENGAGE SLOTS IN THE BACK OF THE TOP OF THE WINDOW MODULE AND MUST BE A REMOVED PRIOR TO REINSTALLATION OF THE WINDOW MODULE. 2. Check if the window module is repairable. a. Look for vertical cracks in the plastic division bars that separate the fixed from the sliding panes. b. Look for separation of the side panes from the plastic frame. c. If either of these conditions are present (usually caused by excessive bending during removal), the module can't be repaired and needs to be replaced with a new module. 3. If the window module is repairable, obtain the Gusset Seal (XL3Z-1542086-AA) and the Standard Butyl Sealing Cord (E69Z-19562-A). 4. Thoroughly clean sheet metal opening in cab of residue from previous butyl seal. Butyl can be used to "blot" butyl off of the sheet metal. If the surface is not properly cleaned of all residue, the window may leak after it is reinstalled. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Customer Interest: > 01-1-11 > Jan > 01 > Sliding Rear Window - Water Leaks to Interior > Page 11802 5. Clean the back of the window module of the previous butyl seal using the methods described. Additionally, clean the top of the window module. Pay particular attention to the lip of the glass that extends above the frame. This lip of glass (the side on top of the module) must be clean for the gusset seal to adhere properly. 6. Place short (25 mm/1 ") sections of standard butyl sealing cord behind the gaps between the side panes of glass and the division bars (Figure 4). Make sure the butyl seats against the plastic frame at the bottom of the gap. If this is not done, the gaps provide a leak path for water to get by the gusset seal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Customer Interest: > 01-1-11 > Jan > 01 > Sliding Rear Window - Water Leaks to Interior > Page 11803 7. Leaving the release tape in place, unpack gusset seal and refer to remaining Figures 1-3 to understand how the seal will be applied to the window module. 8. Notice that a standard butyl sealing cord is applied to the window before the fix is applied (Figure 2). 9. Leaving the release tape on, apply a standard butyl sealing cord to the back of the window module taking care to lay the butyl in the "track" moulded into the plastic window frame. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Customer Interest: > 01-1-11 > Jan > 01 > Sliding Rear Window - Water Leaks to Interior > Page 11804 10. Place window (back side up) on a clean, stable surface with the top edge of the window module facing you. The gusset seal will be applied to the top edge (Figure 3). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Customer Interest: > 01-1-11 > Jan > 01 > Sliding Rear Window - Water Leaks to Interior > Page 11805 11. Check (Figure 1) and find the pre-attached butyl seal that is to be applied to the back edge of the glass. This edge of the gusset seal is thick, rather than flat. Remove the release tape from this butyl seal only. 12. Once installed the gusset seal should extend from one stud on the sloping side of the window module to the opposite stud on the opposite sloping side of the window module (Figures 2 and 3). In the process, it should cover the entire top of the plastic frame behind the glass and down to just above the row of studs across the back of the module. 13. Starting at one side of the module, apply the butyl bead (exposed in Step 12) to the crevice between the back of the glass and the top of the module. It is important that the butyl seals to the glass in order for the gusset seal to not leak. Additionally, try to minimize the protrusion of the seal onto the visible side of the glass. It should be below the rounded edge of the glass. 14. Moving across the top of the module, apply the butyl bead on the edge of the gusset seal to the back of one fixed pane, the plastic lip above the sliding pane, and then across the back edge of the other fixed pane. Make sure that the butyl on the gusset seal seals to the two (2) small pieces of butyl applied in Step 6. 15. Remove the release tape from the standard seal applied in Step 9. Refer to Figure 2 to see how the gusset seal is applied to the standard butyl seal. Starting at one side, stick the back of the gusset seal to the standard butyl seal. At this point, the gusset seal should cover the entire top of the window module down to the row of studs. 16. Remove the release tape from the second butyl strip on the gusset seal. This will seal to the back of the cab. 17. Reinstall the window module according to Section 501-11 of the appropriate year F-150/F-250 LD Workshop Manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION/DESCRIPTION/TIME Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Customer Interest: > 01-1-11 > Jan > 01 > Sliding Rear Window - Water Leaks to Interior > Page 11806 DEALER CODING OASIS CODES: 102000,108000,110000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-2-2 > Feb > 04 > Body - Sliding Back Glass Windnoise/Water Leaks Window Seal: All Technical Service Bulletins Body - Sliding Back Glass Windnoise/Water Leaks Article No. 04-2-2 02/09/04 BODY - BACK GLASS - SLIDING BACK GLASS WINDNOISE/WATER LEAK - SEAL REPLACEMENT FORD: 1999-2003 F-150 ISSUE Some 1999-2003 F-150 vehicles may exhibit windnoise and/or a water leak from the back glass area. ACTION To service, order and install Service kit 3L3Z-1542052-AA. Refer, to the installation instructions included in the kit. It will also be necessary to obtain a tube of Motorcraft Instant Adhesive (TA-19) or equivalent for this repair. NOTE THE KIT APPLIES TO BOTH MANUAL AND POWER SLIDING REAR WINDOWS. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 040202A Install Backlight Sliding 0.6 Hr. Seals (Includes Time To Remove Rear Seat Back On S/Cabs Vehicles Or To Loosen Upper Portion Of Back Panel On Regular Cab And Super Crew Vehicles DEALER CODING CONDITION BASIC PART NO. CODE 15420A26 33 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-1-11 > Jan > 01 > Sliding Rear Window - Water Leaks to Interior Window Seal: All Technical Service Bulletins Sliding Rear Window - Water Leaks to Interior Article No. 01-1-11 01/22/01 WATER LEAK - SLIDING REAR WINDOW - VEHICLES BUILT THROUGH 4/1999 FORD: 1997-1999 F-150, F-250 LD ISSUE Some vehicles may exhibit a water leak around the rear (sliding) window. This may be caused by a crack in the plastic frame around the window and/or deterioration of the butyl seal between plastic frame and cab. ACTION Remove the rear sliding window module and apply a gusset seal. Reinstall the same window module. The gusset seal should reduce the possibility of leaks. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE: PREVIOUSLY, WHEN A SLIDING GLASS REAR WINDOW ON AN F-150/F-250 LD WAS FOUND TO BE LEAKING, THE SERVICE PROCEDURE WAS TO REPLACE THE LEAKING WINDOW MODULE WITH A NEW SLIDING WINDOW MODULE. THE NEW PROCEDURE DETAILED IN THIS TSB DESCRIBES HOW TO USE THE SERVICE FIX SEAL TO REPAIR AND REUSE A REAR WINDOW MODULE. LEAK CHECK THE REAR WINDOW 1. From inside the cab, check to make sure sliding pane is latched closed and area around window is initially dry. 2. Spray water at moderate pressure into margin between window module and halo moulding around window module. 3. From inside cab, check for water dripping down inside window. In particular, look for drips coming down the side (fixed) panes of the window. 4. If water is coming through the seals that seal the sliding pane itself (a less common leak path), the gusset seal will not correct the leak and the window module will need to be replaced. APPLY REAR WINDOW GUSSET SEAL 1. If rear window is found to be leaking, remove it according to Section 501-11 of the appropriate year F-150/F-250 LD Workshop Manual. Take care when removing it to not damage it or the cab sheet metal around it. Try to minimize bending of the window module. NOTE: IF THE VEHICLE WAS BUILT PRIOR TO 2/1998, THE HALO MOULDING (STILL ATTACHED TO THE CAB) THAT NORMALLY FRAMES THE REAR WINDOW MODULE HAS TABS ON IT THAT NEED TO BE REMOVED. THESE TABS (NOT PRESENT ON VEHICLES BUILT AFTER 2/1998) HANG DOWN FROM THE UNDERSIDE OF THE TOP OF THE HALO MOULDING. THEY ENGAGE SLOTS IN THE BACK OF THE TOP OF THE WINDOW MODULE AND MUST BE A REMOVED PRIOR TO REINSTALLATION OF THE WINDOW MODULE. 2. Check if the window module is repairable. a. Look for vertical cracks in the plastic division bars that separate the fixed from the sliding panes. b. Look for separation of the side panes from the plastic frame. c. If either of these conditions are present (usually caused by excessive bending during removal), the module can't be repaired and needs to be replaced with a new module. 3. If the window module is repairable, obtain the Gusset Seal (XL3Z-1542086-AA) and the Standard Butyl Sealing Cord (E69Z-19562-A). 4. Thoroughly clean sheet metal opening in cab of residue from previous butyl seal. Butyl can be used to "blot" butyl off of the sheet metal. If the surface is not properly cleaned of all residue, the window may leak after it is reinstalled. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-1-11 > Jan > 01 > Sliding Rear Window - Water Leaks to Interior > Page 11816 5. Clean the back of the window module of the previous butyl seal using the methods described. Additionally, clean the top of the window module. Pay particular attention to the lip of the glass that extends above the frame. This lip of glass (the side on top of the module) must be clean for the gusset seal to adhere properly. 6. Place short (25 mm/1 ") sections of standard butyl sealing cord behind the gaps between the side panes of glass and the division bars (Figure 4). Make sure the butyl seats against the plastic frame at the bottom of the gap. If this is not done, the gaps provide a leak path for water to get by the gusset seal. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-1-11 > Jan > 01 > Sliding Rear Window - Water Leaks to Interior > Page 11817 7. Leaving the release tape in place, unpack gusset seal and refer to remaining Figures 1-3 to understand how the seal will be applied to the window module. 8. Notice that a standard butyl sealing cord is applied to the window before the fix is applied (Figure 2). 9. Leaving the release tape on, apply a standard butyl sealing cord to the back of the window module taking care to lay the butyl in the "track" moulded into the plastic window frame. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-1-11 > Jan > 01 > Sliding Rear Window - Water Leaks to Interior > Page 11818 10. Place window (back side up) on a clean, stable surface with the top edge of the window module facing you. The gusset seal will be applied to the top edge (Figure 3). Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-1-11 > Jan > 01 > Sliding Rear Window - Water Leaks to Interior > Page 11819 11. Check (Figure 1) and find the pre-attached butyl seal that is to be applied to the back edge of the glass. This edge of the gusset seal is thick, rather than flat. Remove the release tape from this butyl seal only. 12. Once installed the gusset seal should extend from one stud on the sloping side of the window module to the opposite stud on the opposite sloping side of the window module (Figures 2 and 3). In the process, it should cover the entire top of the plastic frame behind the glass and down to just above the row of studs across the back of the module. 13. Starting at one side of the module, apply the butyl bead (exposed in Step 12) to the crevice between the back of the glass and the top of the module. It is important that the butyl seals to the glass in order for the gusset seal to not leak. Additionally, try to minimize the protrusion of the seal onto the visible side of the glass. It should be below the rounded edge of the glass. 14. Moving across the top of the module, apply the butyl bead on the edge of the gusset seal to the back of one fixed pane, the plastic lip above the sliding pane, and then across the back edge of the other fixed pane. Make sure that the butyl on the gusset seal seals to the two (2) small pieces of butyl applied in Step 6. 15. Remove the release tape from the standard seal applied in Step 9. Refer to Figure 2 to see how the gusset seal is applied to the standard butyl seal. Starting at one side, stick the back of the gusset seal to the standard butyl seal. At this point, the gusset seal should cover the entire top of the window module down to the row of studs. 16. Remove the release tape from the second butyl strip on the gusset seal. This will seal to the back of the cab. 17. Reinstall the window module according to Section 501-11 of the appropriate year F-150/F-250 LD Workshop Manual. PARTS BLOCK OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage OPERATION/DESCRIPTION/TIME Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-1-11 > Jan > 01 > Sliding Rear Window - Water Leaks to Interior > Page 11820 DEALER CODING OASIS CODES: 102000,108000,110000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Seal: > 01-13-7 > Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift Planetary Gears: All Technical Service Bulletins A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift Article No. 01-13-7 07/09/01 ^ NOISE - "CLUNK" NOISE HEARD ON 2-1 DOWNSHIFT VEHICLES EQUIPPED WITH 4R70W AUTOMATIC TRANSMISSION ^ TRANSMISSION - 4R70W - "CLUNK" NOISE HEARD FROM TRANSMISSION ON 2-1 DOWNSHIFT FORD: 1999-2001 CROWN VICTORIA, MUSTANG 1999 F-250 LD 1999-2001 E SERIES, EXPEDITION, EXPLORER, F-150 LINCOLN: 1999-2001 TOWN CAR MERCURY: 1999-2001 GRAND MARQUIS, MOUNTAINEER ISSUE Some vehicles equipped with a 4R70W automatic transmission may exhibit a "clunk" noise during the 2-1 downshift event. The "clunk" noise will be consistent in nature, and will occur during most 2-1 downshifts. This may be caused by a Planet Support Spring that is out of position. ACTION Check for the correct installation of the Planet Support Spring. If the spring is not installed correctly, the Planetary Gear Support will make contact with the transmission case during the 2-1 downshift, causing the "clunk" noise. Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE THE "CLUNK" NOISE DESCRIBED IN THIS ARTICLE SHOULD NOT BE CONFUSED WITH HARSH/ROUGH 2-1 DOWNSHIFT CONDITION. IF A HARSH/ROUGH 2-1 SHIFT CONDITION IS PRESENT, FOLLOW NORMAL WORKSHOP MANUAL DIAGNOSTIC PROCEDURES. 1. Use Chassis Ears (Rotunda number 107-R2102 or equivalent) to verify the "clunk" noise is originating from the transmission during the 2-1 downshift event. NOTE IF THE NOISE IS NOT ORIGINATING FROM THE TRANSMISSION DO NOT CONTINUE WITH THIS SERVICE PROCEDURE. USE THE CHASSIS EARS TO HELP PINPOINT THE ORIGIN OF THE NOISE, THEN DIAGNOSE AND REPAIR AS NEEDED. 2. Raise and support vehicle. Refer to Workshop Manual Section 100-02. 3. Check for correct torque on the following chassis & drivetrain components: ^ Driveshaft to Pinion Flange fasteners ^ Upper and Lower Control Arm fasteners (car applications) ^ Rear Leaf Spring Fasteners (truck applications) ^ Rear Shock Absorber fasteners ^ Transmission Mount and Crossmember fasteners 4. If any discrepancies are found, correct and test drive vehicle to verify repair. If condition is not corrected, continue to Step 5. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Seal: > 01-13-7 > Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 11826 5. Remove the transmission from the vehicle and disassemble down to and including the Center Support Retaining Ring. Refer to Workshop Manual section 307-01. 6. Note the position of the Planet Support Spring. Compare to the correct installation which is illustrated in Figure 1. One tang of the Planet Support Spring should be loaded against the transmission case. The other tang should be loaded against the Planetary Gear Support. 7. Unless the Planet Support Spring is damaged, it may be reinstalled in the transmission correctly. If the spring is damaged, replace with part number F5AZ-7F277-AA. 8. Install the Planet Support Spring in the position illustrated in Figure 1. Use a flat/wide tool, that will apply equal force across the spring. This will ensure the spring is installed squarely with the tangs loading the Transmission Case on one side and the Planetary Gear Support on the other. 9. Reassemble and install the transmission. Replace the Pump Gasket during reassembly. Part number F2VY-7A136-A. 10. Lower vehicle, refill fluid to correct level and verity repair. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Seal: > 01-13-7 > Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 11827 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Seal: > 01-13-7 > Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 11828 Operation/Description/Time DEALER CODING CONDITION BASIC PART NO. CODE 7F277 07 OASIS CODES: 502000, 504000, 597997 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Seal: > 01-13-7 > Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 11834 5. Remove the transmission from the vehicle and disassemble down to and including the Center Support Retaining Ring. Refer to Workshop Manual section 307-01. 6. Note the position of the Planet Support Spring. Compare to the correct installation which is illustrated in Figure 1. One tang of the Planet Support Spring should be loaded against the transmission case. The other tang should be loaded against the Planetary Gear Support. 7. Unless the Planet Support Spring is damaged, it may be reinstalled in the transmission correctly. If the spring is damaged, replace with part number F5AZ-7F277-AA. 8. Install the Planet Support Spring in the position illustrated in Figure 1. Use a flat/wide tool, that will apply equal force across the spring. This will ensure the spring is installed squarely with the tangs loading the Transmission Case on one side and the Planetary Gear Support on the other. 9. Reassemble and install the transmission. Replace the Pump Gasket during reassembly. Part number F2VY-7A136-A. 10. Lower vehicle, refill fluid to correct level and verity repair. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Seal: > 01-13-7 > Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 11835 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Seal: > 01-13-7 > Jul > 01 > A/T - 4R70W Clunk Noise on 2nd to 1st Gear Downshift > Page 11836 Operation/Description/Time DEALER CODING CONDITION BASIC PART NO. CODE 7F277 07 OASIS CODES: 502000, 504000, 597997 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > Customer Interest: > 04-5-7 > Mar > 04 > Body - Front Window(s) Pop/Thump Noise at End of Travel Window Track: Customer Interest Body - Front Window(s) Pop/Thump Noise at End of Travel Article No. 04-5-7 03/22/04 BODY - FRONT WINDOW(S) - POP/THUMP NOISE AT END OF WINDOW TRAVEL AND/OR DRIVER'S WINDOW BOUNCE BACK AND REVERSE TO MID-POSITION FORD: 1997-2003 F-150 1997-2004 EXPEDITION LINCOLN: 1998-2004 NAVIGATOR ISSUE Some 1997-2004 Expedition, 1998-2004 Navigator built through 04/01/2004 and 1997-2003 F-150, may exhibit a pop/thump noise at the end of window travel when either front window is rolled up. Some 2003-2004 Navigator vehicles may also exhibit a driver's door glass bounce back and reverse to a mid-position. The condition may exist when the vehicle is stationary or traveling at low speeds, however the condition will become more pronounced when traveling at higher speeds. This may be due to the window glass being too far outboard and catching on the glass run before seating. ACTION To service, adjust the window's travel path inward, by bending the flange on which the glass run is mounted. Refer to the Service Procedure below. SERVICE PROCEDURE 1. Remove inner door panel, refer to Workshop Manual Section 501-11. 2. Remove exterior mirror, refer to Workshop Manual Section 501-09. 3. Torque door glass retainers for regulator to door, window glass to regulator, and both front and rear window runs to 11 N.m (8 lb-ft). 4. Lower door glass to position it out of the way. 5. Remove inner and outer belt molding. 6. Position aside front window run. a. Remove retainer. b. Position outside of work area. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > Customer Interest: > 04-5-7 > Mar > 04 > Body - Front Window(s) Pop/Thump Noise at End of Travel > Page 11845 7. Bend flange inboard about 10 degrees, using a pair of sheet metal clamp locking pliers (Figure 1). Starting at the bend at the top of the sail plate, and working down approximately 25.40 cm (10") (Figure 2). NOTE TAKE CARE NOT TO OVER BEND FLANGE, THIS MAY INDUCE WIND NOISE. 8. Reposition front window run. a. Install retainer. b. Torque retainer to 11 N.m (8 lb-ft). 9. Install inner and outer belt molding. 10. Install exterior mirror, refer to Workshop Manual Section 501-09. 11. Install inner door panel, refer to Workshop Manual Section 501-11. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > Customer Interest: > 04-5-7 > Mar > 04 > Body - Front Window(s) Pop/Thump Noise at End of Travel > Page 11846 12. 2003-2004 Navigator vehicles, re-initialize drivers window according to Workshop Manual Section 501-11. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 7820125 42 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-5-7 > Mar > 04 > Body - Front Window(s) Pop/Thump Noise at End of Travel Window Track: All Technical Service Bulletins Body - Front Window(s) Pop/Thump Noise at End of Travel Article No. 04-5-7 03/22/04 BODY - FRONT WINDOW(S) - POP/THUMP NOISE AT END OF WINDOW TRAVEL AND/OR DRIVER'S WINDOW BOUNCE BACK AND REVERSE TO MID-POSITION FORD: 1997-2003 F-150 1997-2004 EXPEDITION LINCOLN: 1998-2004 NAVIGATOR ISSUE Some 1997-2004 Expedition, 1998-2004 Navigator built through 04/01/2004 and 1997-2003 F-150, may exhibit a pop/thump noise at the end of window travel when either front window is rolled up. Some 2003-2004 Navigator vehicles may also exhibit a driver's door glass bounce back and reverse to a mid-position. The condition may exist when the vehicle is stationary or traveling at low speeds, however the condition will become more pronounced when traveling at higher speeds. This may be due to the window glass being too far outboard and catching on the glass run before seating. ACTION To service, adjust the window's travel path inward, by bending the flange on which the glass run is mounted. Refer to the Service Procedure below. SERVICE PROCEDURE 1. Remove inner door panel, refer to Workshop Manual Section 501-11. 2. Remove exterior mirror, refer to Workshop Manual Section 501-09. 3. Torque door glass retainers for regulator to door, window glass to regulator, and both front and rear window runs to 11 N.m (8 lb-ft). 4. Lower door glass to position it out of the way. 5. Remove inner and outer belt molding. 6. Position aside front window run. a. Remove retainer. b. Position outside of work area. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-5-7 > Mar > 04 > Body - Front Window(s) Pop/Thump Noise at End of Travel > Page 11852 7. Bend flange inboard about 10 degrees, using a pair of sheet metal clamp locking pliers (Figure 1). Starting at the bend at the top of the sail plate, and working down approximately 25.40 cm (10") (Figure 2). NOTE TAKE CARE NOT TO OVER BEND FLANGE, THIS MAY INDUCE WIND NOISE. 8. Reposition front window run. a. Install retainer. b. Torque retainer to 11 N.m (8 lb-ft). 9. Install inner and outer belt molding. 10. Install exterior mirror, refer to Workshop Manual Section 501-09. 11. Install inner door panel, refer to Workshop Manual Section 501-11. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-5-7 > Mar > 04 > Body - Front Window(s) Pop/Thump Noise at End of Travel > Page 11853 12. 2003-2004 Navigator vehicles, re-initialize drivers window according to Workshop Manual Section 501-11. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage DEALER CODING CONDITION BASIC PART NO. CODE 7820125 42 Disclaimer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Track: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms Air Flow Meter/Sensor: All Technical Service Bulletins Engine - Lean Driveability Symptoms Article No. 98-23-10 11/23/98 MASS AIR FLOW (MAF) - SENSOR CONTAMINATION - SERVICE TIP FORD: 1990-97 THUNDERBIRD 1990-99 MUSTANG, TAURUS SHO 1991-99 CROWN VICTORIA, ESCORT, TAURUS 1992-94 TEMPO 1993-97 PROBE 1995-99 CONTOUR LINCOLN-MERCURY: 1990-97 COUGAR 1991-99 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1992-94 TOPAZ 1993-98 MARK VIII 1995-99 MYSTIQUE LIGHT TRUCK: 1990 BRONCO II 1990-97 AEROSTAR 1990-99 RANGER 1991-99 EXPLORER 1994-96 BRONCO 1994-97 F SUPER DUTY, F-250 HD 1994-99 ECONOLINE, F-150, F-250 LD, F-350 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 F-250 HD, SUPER DUTY F SERIES ISSUE This TSB article is a diagnostic procedure to address vehicles that exhibit lean driveability symptoms and may or may not have any Diagnostic Trouble Codes (DTCs) stored in memory. ACTION Follow the diagnostic procedures described in the following Service Tip. The revised diagnostic procedure is a more accurate means of diagnosing the symptoms. SERVICE TIP MASS AIR FLOW (MAF) DISCUSSION MAF sensors can get contaminated from a variety of sources: dirt, oil, silicon, spider webs, potting compound from the sensor itself, etc. When a MAF sensor gets contaminated, it skews the transfer function such that the sensor over-estimates air flow at idle (causes the fuel system to go rich) and under-estimates air flow at high air flows (causes fuel system to go lean). This means Long Term Fuel Trims will learn lean (negative) corrections at idle and learn rich (positive) corrections at higher air flows. If vehicle is driven at Wide Open Throttle (WOT) or high loads, the fuel system normally goes open loop rich to provide maximum power. If the MAF sensor is contaminated, the fuel system will actually be lean because of under-estimated air flow. During open loop fuel operation, the vehicle applies Long Term Fuel Trim corrections that have been learned during closed loop operation. These corrections are often lean corrections learned at lower air flows. This combination of under-estimated air flow and lean fuel trim corrections can result in spark knock/detonation and lack of power concerns at WOT and high loads. One of the indicators for diagnosing this condition is barometric pressure. Barometric pressure (BARO) is inferred by the Powertrain Control Module (PCM) software at part throttle and WOT (there is no actual BARO sensor on MAF-equipped vehicles, except for the 3.8L Supercharged engine). At high air flows, a contaminated MAF sensor will under-estimate air flow coming into the engine, hence the PCM infers that the vehicle is operating at a higher altitude. The BARO reading is stored in Keep Alive Memory (KAM) after it is updated. Other indicators are Long Term Fuel Trim and MAF Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Track: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 11859 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Track: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 11860 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Track: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 11866 voltage at idle. NOTE THE FOLLOWING PROCEDURE MAY ALSO BE USED TO DIAGNOSE VEHICLES THAT DO NOT HAVE FUEL SYSTEM/HO2S SENSOR DTCS. Symptoms ^ Lack of Power ^ Spark Knock/Detonation ^ Buck/Jerk ^ Hesitation/Surge on Acceleration ^ Malfunction Indicator Lamp (MIL) Illuminated DTCs P0171, P0172, P0174, P0175 may be stored in memory OBDII DTCs ^ P0171, P0174 (Fuel system lean, Bank 1 or 2) ^ P0172, P0175, (Fuel system rich, Bank 1 or 2) ^ P1130, P1131, P1132, (HO2S11 lack of switching, Bank 1) ^ P1150, P1151, P1152, (HO2S21 lack of switching, Bank 2) OBDI DTCs ^ 181, 189 (Fuel system lean, Bank 1 or 2) ^ 179, 188 (Fuel system rich, Bank 1 or 2) ^ 171, 172, 173 (HO2S11 lack of switching, Bank 1) ^ 175, 176, 177 (HO2S21 lack of switching, Bank 2) ^ 184, 185 (MAF higher/lower than expected) ^ 186, 187 (Injector pulse width higher/lower than expected) NOTE: DO NOT DISCONNECT THE BATTERY. IT WILL ERASE KEEP ALIVE MEMORY AND RESET LONG TERM FUEL TRIM AND BARO TO THEIR STARTING/BASE VALUES. THE BARO PARAMETER IDENTIFICATION DISPLAY (PID) IS USED FOR THIS DIAGNOSTIC PROCEDURE. ALL OBDII APPLICATIONS HAVE THIS PID AVAILABLE. THERE ARE SOME OBDI VEHICLES THAT DO NOT HAVE THE BARO PID, FOR THESE VEHICLES OMIT THE BARO CHECK AND REFER ONLY TO STEPS 2, 3, AND 4 IN THE DIAGNOSTIC PROCEDURE. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Track: > 98-23-10 > Nov > 98 > Engine - Lean Driveability Symptoms > Page 11867 1. Look at the BARO PID. Refer to the Barometric Pressure Reference Chart in this article. At sea level, BARO should read about 159 Hz (29.91 in. Hg). As a reference, Denver, Colorado at 1524 meters (5000 ft.) altitude should be about 144 Hz (24.88 in.Hg). Normal learned BARO variability is up to +/- 6 Hz (+/- 2 in. Hg.). If BARO indicates a higher altitude than you are not at (7 or more Hz lower than expected), you may have MAF contamination. If available, Service Bay Diagnostic System (SBDS) has a Manifold Absolute Pressure (MAP) sensor that can be used as a barometric pressure reference. Use "MAP/BARO" test under "Powertrain," "Testers and Meters." Ignore the hookup screen. Connect GP2 to the reference MAP on the following screen. NOTE REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL INCHES OF MERCURY (+/- 3 Hz, +/- 1 in. Hg.). NOTE BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS. THEREFORE, A VEHICLE WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY, SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO UPDATE. 2. On a fully warmed up engine, look at Long Term Fuel Trim at idle, in Neutral, A/C off, (LONGFT1 and/or LONGFT2 PIDs). If it is more negative than -12%, the fuel system has learned lean corrections which may be due to the MAF sensor over-estimating air flow at idle. Note that both Banks 1 and 2 will exhibit negative corrections for 2-bank system. If only one bank of a 2-bank system has negative corrections, the MAF sensor is probably not contaminated. 3. On a fully warmed up engine, look at MAF voltage at idle, in Neutral, A/C off (MAF V PID). If it's 30% greater than the nominal MAF V voltage listed in the Powertrain Control/Emissions Diagnosis (PC/ED) Diagnostic Value Reference Charts for your vehicle, or greater than 1.1 volts as a rough guide, the MAF sensor is over-estimating air flow at idle. 4. If at least tow of the previous three steps are true, proceed to disconnect the MAF sensor connector. This puts the vehicle into Failure Mode and Effects Management (FMEM). In FMEM mode, air flow is inferred by using rpm and throttle position instead of reading the MAF sensor. (In addition, the BARO value is reset to a base/unlearned value.) If the lean driveability symptoms go away, the MAF sensor is probably contaminated and should be replaced. If the lean driveability symptoms do not go away, go to the PC/ED Service Manual for the appropriate diagnostics. NOTE DUE TO INCREASINGLY STRINGENT EMISSION/OBDII REQUIREMENTS, IT IS POSSIBLE FOR SOME VEHICLES WITH MAF SENSOR CONTAMINATION TO SET FUEL SYSTEM DTCs AND ILLUMINATE THE MIL WITH NO DRIVEABILITY CONCERNS. DISCONNECTING THE MAF ON THESE VEHICLES WILL, THEREFORE, PRODUCE NO IMPROVEMENTS IN DRIVEABILITY. IN THESE CASES, IF THE BARO, LONGFT1, LONGFT2, AND MAF V PIDs INDICATE THAT THE MAF IS CONTAMINATED, PROCEED TO REPLACE THE MAF SENSOR. After replacing the MAF sensor, disconnect the vehicle battery (5 minutes, minimum to reset KAM, or on newer vehicles, use the "KAM Reset" feature on the New Generation Star (NGS) Tester and verify that the lean driveability symptoms are gone. OTHER APPLICABLE ARTICLES:: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 206000, 610000, 610500, 610600, 610700, 611000, 611500, 612000, 612500, 614000, 614500, 614600, 698298 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest for Windshield: > 99-2-3 > Feb > 99 > Windshield - Water Leaks Windshield: Customer Interest Windshield - Water Leaks Article No. 99-2-3 ^ WATER LEAKS - WINDSHIELD SEALING - SERVICE TIP ^ WINDSHIELD - SEALING - SERVICE TIP FORD: 1995-97 PROBE, THUNDERBIRD 1995-99 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-97 COUGAR 1995-98 MARK VIII 1995-99 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER LIGHT TRUCK: 1995-97 AEROSTAR, F SUPER DUTY 1995-99 ECONOLINE, EXPLORER, F-150, F-250 HD, F-250 LD, F-350, RANGER, VILLAGER, WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE The customer may report a water leak from the windshield. This may be caused by a skip or a void in the production sealer somewhere around the periphery of the windshield. ACTION Apply a bead of Liquid Butyl Sealer (F8AZ-19554-CA) under the weatherstrip around the periphery of the windshield. Refer to the appropriate Service or Workshop Manual for weatherstrip removal where necessary. NOTE DUE TO DIFFICULTY IN DETERMINING THE EXACT LOCATION OF A WATER LEAK, IT MAY BE IDEAL TO SEAL THE ENTIRE WINDSHIELD PERIPHERY (SIDES, TOP AND BOTTOM) TO ENSURE REPAIR OF THE LEAK. The following is the labor operation to be used for this repair and a chart providing Windshield Sealing Labor Times: ^ 03100B PART NUMBER PART NAME F8AZ-19554-CA Liquid Butyl Sealer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest for Windshield: > 99-2-3 > Feb > 99 > Windshield - Water Leaks > Page 11876 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 110000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 99-2-3 > Feb > 99 > Windshield - Water Leaks Windshield: All Technical Service Bulletins Windshield - Water Leaks Article No. 99-2-3 ^ WATER LEAKS - WINDSHIELD SEALING - SERVICE TIP ^ WINDSHIELD - SEALING - SERVICE TIP FORD: 1995-97 PROBE, THUNDERBIRD 1995-99 CONTOUR, CROWN VICTORIA, ESCORT, MUSTANG, TAURUS LINCOLN-MERCURY: 1995-97 COUGAR 1995-98 MARK VIII 1995-99 CONTINENTAL, GRAND MARQUIS, MYSTIQUE, SABLE, TOWN CAR, TRACER LIGHT TRUCK: 1995-97 AEROSTAR, F SUPER DUTY 1995-99 ECONOLINE, EXPLORER, F-150, F-250 HD, F-250 LD, F-350, RANGER, VILLAGER, WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE The customer may report a water leak from the windshield. This may be caused by a skip or a void in the production sealer somewhere around the periphery of the windshield. ACTION Apply a bead of Liquid Butyl Sealer (F8AZ-19554-CA) under the weatherstrip around the periphery of the windshield. Refer to the appropriate Service or Workshop Manual for weatherstrip removal where necessary. NOTE DUE TO DIFFICULTY IN DETERMINING THE EXACT LOCATION OF A WATER LEAK, IT MAY BE IDEAL TO SEAL THE ENTIRE WINDSHIELD PERIPHERY (SIDES, TOP AND BOTTOM) TO ENSURE REPAIR OF THE LEAK. The following is the labor operation to be used for this repair and a chart providing Windshield Sealing Labor Times: ^ 03100B PART NUMBER PART NAME F8AZ-19554-CA Liquid Butyl Sealer Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 99-2-3 > Feb > 99 > Windshield - Water Leaks > Page 11882 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 110000 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 11883 Windshield: Description and Operation The windshield glass: ^ Is standard plastic and glass laminate safety glass. ^ Is bonded to the window opening flange with urethane sealant. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 11884 Windshield: Service and Repair Interior Auto Glass Cut-Out Knife Kit Special Tool(s) REMOVAL 1. Remove the cowl top vent panels. 2. Remove the assist handle screw covers. 3. Remove the assist handle screws. 4. Remove the assist handle. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 11885 5. Remove the LH and RH windshield side garnish mouldings. 6. Remove the inside rear view mirror. 7. Remove the inside visor. 1 Remove the screws. 2 Remove the inside visor. 8. Remove the center visor clip. 1 Remove the screws. 2 Remove the center visor clip. 9. Lower the front portion of the roof trim panel. 10. Remove the upper windshield weatherstrip. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 11886 11. Remove the LH and RH windshield mouldings. 12. Mark the outside of the windshield glass with a wax pencil to avoid damaging the glass stops when cutting urethane. 13. Lubricate the urethane sealant with water to aid Interior Auto Glass Cut-Out Knife Kit when cutting the urethane sealant. 14. Use Interior Auto Glass Cut-Out Knife Kit to cut the urethane from the windshield glass. ^ Insert the blade into the urethane at the top middle and work toward the bottom corners. WARNING: To prevent glass splinters from entering the eyes or cutting hands, wear safety glasses and heavy gloves when cutting the glass from the vehicle. 15. Trim the excess urethane from the outside edge of the windshield glass. 16. Carefully remove the windshield glass. NOTE: Removing the windshield glass requires more than one technician. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 11887 17. Trim the remaining urethane on the pinch weld to within specification. ^ The old urethane surface should be smooth and free of cuts and contamination. INSTALLATION CAUTION: After replacing the urethane installed glass, the vehicle should not be driven until the urethane has cured. The curing times at temperatures above 13°C (55°F) and relative humidity above 50% is 12-24 hours (decreasing at higher temperatures and lower humidities). Inadequate curing of the urethane may adversely affect the strength of the urethane sealant bond. 1. Check the pinch weld for damaged sheet metal, raised sheet metal at the spot welds, rust or foreign material that could cause glass damage. 2. Use a wool applicator to apply Urethane Metal Primer or equivalent meeting Ford specification WSB-M2G234-C to any exposed metal on the pinch weld. 3. Apply (A) 8 mm foam butyl (part of EOAZ-19562-A) or equivalent meeting Ford specification WSB-M2G234-C to the (B) pinch weld. 4. Remove excess urethane from the windshield glass. 5. Clean the inside of the glass surface with an alcohol-free cleaner. 6. Apply Urethane Glass Prep (part of EOAZ-19562-A) or equivalent meeting Ford specification WSB-M2G234-C twice around the glass surface to be urethaned. NOTE: ^ Apply with deliberate strokes, making sure not to overlap the applied area. ^ Wipe off the Urethane Glass Prep immediately after application because it flash dries. 7. Cut the urethane applicator tip to specification. 8. Apply a urethane bead to the pinch weld just outside the foam butyl dam. 9. Install the inside rear view mirror. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 11888 10. Position the windshield glass. 11. Install the upper windshield weatherstrip. 12. Paddle the excess urethane from the two sides of the windshield glass. NOTE: Use one continuous stroke when removing the excess urethane. 13. If necessary, remove excess urethane from the outside surface of the windshield glass. 14. Install the LH and RH windshield mouldings. 15. Position the roof trim panel. 16. Install the center visor clip. 1 Position the center visor clip. 2 Install the screws. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Page 11889 17. Install the inside visor. 1 Position the inside visor. 2 Install the screws. 18. Install the LH and RH windshield side garnish mouldings. 19. Install the assist handle. 1 Position the assist handle. 2 Install the screws. 3 Install the covers. 20. Install the cowl top vent panel. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations Windshield Washer Relay: Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 11895 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 11896 Windshield Washer Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 11897 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay Wiper Relay: Locations Wiper High/Low Relay Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 11902 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 11903 Wiper Relay: Locations Wiper Run/Park Relay Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 11904 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 11905 Wiper Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 11906 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 11911 Windshield Washer Switch: Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 11912 Windshield Washer Switch: Description and Operation The integrated multifunction switch is mounted to the LH side of the steering column and controls the turn signal, headlamp dimmer/flash-to-pass, windshield wiper/washer and hazard warning. The ignition switch is mounted below the steering column and is activated using the ignition key and rotating the key lock cylinder on the steering column. If equipped with manual transmission, the key release lever prevents rotation of the ignition cylinder to LOCK or ACC positions unless the lever is depressed. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis Windshield Washer Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11915 Windshield Washer Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11916 Windshield Washer Switch: Diagnostic Trouble Code Descriptions GEM/CTM Active Command Index Part 1 Of 2 Part 2 Of 2 GEM/CTM Diagnostic Trouble Code (DTC) Index Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11917 Part 1 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11918 Part 2 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11919 Part 3 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11920 Part 4 Of 4 GEM/CTM Parameter Identification (PID) Index Part 1 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11921 Part 2 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11922 Part 3 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11923 Windshield Washer Switch: Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11924 Windshield Washer Switch: Testing and Inspection Flow of Diagnosis 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Initial Inspection and Diagnostic Overview Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11925 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures GEM/CTM Active Command Index Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11926 Part 1 Of 2 Part 2 Of 2 GEM/CTM Diagnostic Trouble Code (DTC) Index Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11927 Part 1 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11928 Part 2 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11929 Part 3 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11930 Part 4 Of 4 GEM/CTM Parameter Identification (PID) Index Part 1 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11931 Part 2 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11932 Part 3 Of 3 Symptom Related Diagnostic Procedures Part 1 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11933 Part 2 Of 2 Test A: No Communication With the GEM or CTM Test A1 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11934 Test A2 - A3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11935 Test A4 - A5 Test B: Unable to Enter Self-Test Test B1 Component Tests and General Diagnostics Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11936 Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11937 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 11938 Windshield Washer Switch: Service and Repair MULTIFUNCTION SWITCH Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1. Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2. Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder 3. Twist the tilt wheel handle and shank and remove. 4. NOTE: Move gear selector to lowest position to access steering column opening cover. Release the four clips and remove the steering column opening cover. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 11939 5. Remove the upper and lower steering column shrouds. 1. Remove the three screws. 2. Remove the lower steering column shroud. 3. Remove the upper steering column shroud. 6. Remove the mult1 function switch. 1. Remove the two screws. 2. Disconnect the electrical connectors. 3. Remove the mult1 function switch. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 11940 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 11944 Wiper Switch: Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 11945 Wiper Switch: Description and Operation The integrated multifunction switch is mounted to the LH side of the steering column and controls the turn signal, headlamp dimmer/flash-to-pass, windshield wiper/washer and hazard warning. The ignition switch is mounted below the steering column and is activated using the ignition key and rotating the key lock cylinder on the steering column. If equipped with manual transmission, the key release lever prevents rotation of the ignition cylinder to LOCK or ACC positions unless the lever is depressed. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis Wiper Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11948 Wiper Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11949 Wiper Switch: Diagnostic Trouble Code Descriptions GEM/CTM Active Command Index Part 1 Of 2 Part 2 Of 2 GEM/CTM Diagnostic Trouble Code (DTC) Index Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11950 Part 1 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11951 Part 2 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11952 Part 3 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11953 Part 4 Of 4 GEM/CTM Parameter Identification (PID) Index Part 1 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11954 Part 2 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11955 Part 3 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11956 Wiper Switch: Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11957 Wiper Switch: Testing and Inspection Flow of Diagnosis 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Initial Inspection and Diagnostic Overview Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11958 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures GEM/CTM Active Command Index Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11959 Part 1 Of 2 Part 2 Of 2 GEM/CTM Diagnostic Trouble Code (DTC) Index Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11960 Part 1 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11961 Part 2 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11962 Part 3 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11963 Part 4 Of 4 GEM/CTM Parameter Identification (PID) Index Part 1 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11964 Part 2 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11965 Part 3 Of 3 Symptom Related Diagnostic Procedures Part 1 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11966 Part 2 Of 2 Test A: No Communication With the GEM or CTM Test A1 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11967 Test A2 - A3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11968 Test A4 - A5 Test B: Unable to Enter Self-Test Test B1 Test C: the Ignition Switch Is Inoperative Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11969 Test C1 Test D: No Power In ACC Test D1 Test E: No Power In Run Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11970 Test E1 Test E1 - E2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11971 Test F: No Power In Start Test F1 - F2 Component Tests and General Diagnostics Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11972 Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11973 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 11974 Wiper Switch: Service and Repair MULTIFUNCTION SWITCH Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1. Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2. Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder 3. Twist the tilt wheel handle and shank and remove. 4. NOTE: Move gear selector to lowest position to access steering column opening cover. Release the four clips and remove the steering column opening cover. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 11975 5. Remove the upper and lower steering column shrouds. 1. Remove the three screws. 2. Remove the lower steering column shroud. 3. Remove the upper steering column shroud. 6. Remove the mult1 function switch. 1. Remove the two screws. 2. Disconnect the electrical connectors. 3. Remove the mult1 function switch. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 11976 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair Windshield Washer Pump: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the jack handle from the windshield washer reservoir. 3. Disconnect the windshield washer pump electrical connector. 4. Remove the windshield washer reservoir screws. 5. Disconnect the windshield washer hose. NOTE: Windshield washer fluid should be collected in a container after the windshield washer hose is disconnected. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Service and Repair > Page 11980 6. Remove the windshield washer reservoir. 7. Remove the windshield washer pump. INSTALLATION 1. To install, reverse the removal procedure. ^ Fill the windshield washer reservoir with ultra-clear windshield washer concentrate C9AZ-19550-AC or BC or equivalent meeting Ford specification ESR-M17P5-A. CAUTION: Do not make electrical connection prior to filling the windshield washer reservoir. Do not operate the windshield washer pump prior to filling the windshield washer reservoir. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations Windshield Washer Relay: Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 11984 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 11985 Windshield Washer Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations > Page 11986 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Specifications Windshield Washer Reservoir: Specifications Windshield Washer Reservoir Screws ........................................................................................................................................... 4.6-5.4 Nm (42-48 in lbs) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Specifications > Page 11990 Windshield Washer Reservoir: Service and Repair REMOVAL 1. Disconnect the battery ground cable. 2. Disconnect the jack handle from the windshield washer reservoir. 3. Disconnect the windshield washer pump electrical connector. 4. Remove the windshield washer reservoir screws. 5. Disconnect the windshield washer hose. NOTE: Windshield washer fluid should be collected in a container after the windshield washer hose is disconnected. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Specifications > Page 11991 6. Remove the windshield washer reservoir. 7. Remove the windshield washer pump. INSTALLATION 1. To install, reverse the removal procedure. ^ Fill the windshield washer reservoir with ultra-clear windshield washer concentrate C9AZ-19550-AC or BC or equivalent meeting Ford specification ESR-M17P5-A. CAUTION: Do not make electrical connection prior to filling the windshield washer reservoir. Do not operate the windshield washer pump prior to filling the windshield washer reservoir. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 11995 Windshield Washer Switch: Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 11996 Windshield Washer Switch: Description and Operation The integrated multifunction switch is mounted to the LH side of the steering column and controls the turn signal, headlamp dimmer/flash-to-pass, windshield wiper/washer and hazard warning. The ignition switch is mounted below the steering column and is activated using the ignition key and rotating the key lock cylinder on the steering column. If equipped with manual transmission, the key release lever prevents rotation of the ignition cylinder to LOCK or ACC positions unless the lever is depressed. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis Windshield Washer Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 11999 Windshield Washer Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12000 Windshield Washer Switch: Diagnostic Trouble Code Descriptions GEM/CTM Active Command Index Part 1 Of 2 Part 2 Of 2 GEM/CTM Diagnostic Trouble Code (DTC) Index Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12001 Part 1 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12002 Part 2 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12003 Part 3 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12004 Part 4 Of 4 GEM/CTM Parameter Identification (PID) Index Part 1 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12005 Part 2 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12006 Part 3 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12007 Windshield Washer Switch: Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12008 Windshield Washer Switch: Testing and Inspection Flow of Diagnosis 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Initial Inspection and Diagnostic Overview Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12009 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures GEM/CTM Active Command Index Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12010 Part 1 Of 2 Part 2 Of 2 GEM/CTM Diagnostic Trouble Code (DTC) Index Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12011 Part 1 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12012 Part 2 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12013 Part 3 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12014 Part 4 Of 4 GEM/CTM Parameter Identification (PID) Index Part 1 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12015 Part 2 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12016 Part 3 Of 3 Symptom Related Diagnostic Procedures Part 1 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12017 Part 2 Of 2 Test A: No Communication With the GEM or CTM Test A1 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12018 Test A2 - A3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12019 Test A4 - A5 Test B: Unable to Enter Self-Test Test B1 Component Tests and General Diagnostics Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12020 Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12021 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 12022 Windshield Washer Switch: Service and Repair MULTIFUNCTION SWITCH Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1. Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2. Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder 3. Twist the tilt wheel handle and shank and remove. 4. NOTE: Move gear selector to lowest position to access steering column opening cover. Release the four clips and remove the steering column opening cover. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 12023 5. Remove the upper and lower steering column shrouds. 1. Remove the three screws. 2. Remove the lower steering column shroud. 3. Remove the upper steering column shroud. 6. Remove the mult1 function switch. 1. Remove the two screws. 2. Disconnect the electrical connectors. 3. Remove the mult1 function switch. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing and Inspection > Page 12024 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications > Adjustment Specifications Wiper Arm: Specifications Adjustment Specifications Windshield Wiper Blade and Bottom of Windshield Glass RH ....................................................................................................................................................... ............................................ 65-93 mm (2.6-3.7 in) LH ....................................................................... ............................................................................................................................ 45-75 mm (1.7-3.0 in) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications > Adjustment Specifications > Page 12029 Wiper Arm: Specifications Torque Specifications Windshield Wiper Pivot Arm Nuts .................................................................................................................................................. 30-40 Nm (23-29 ft lbs) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications > Page 12030 Wiper Arm: Adjustments 1. Cycle and park the windshield wipers. 2. Verify the distance between the center of the (A) RH windshield wiper blade and the (C) bottom of the windshield glass is within specification. 3. Verify the distance between the center of the (B) LH windshield wiper blade and the (C) bottom of the windshield glass is within specification. 4. If the distance is not within specification, remove the windshield wiper pivot arm and reposition to specification. 1 Remove the pivot arm nut cover. 2 Remove the nut. 3 Remove and reposition the windshield wiper pivot arm. 5. Tighten the windshield wiper pivot arm nuts. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications > Page 12031 Wiper Arm: Service and Repair REMOVAL 1. Remove the windshield wiper pivot arm. 1 Remove the pivot arm nut cover. 2 Remove the nut. 3 Remove the windshield wiper pivot arm. INSTALLATION 1. To install, reverse the removal procedure. ^ Adjust the windshield wiper pivot arms. See: Adjustments Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications Wiper Motor: Specifications Windshield Wiper Motor Bolts .................................................................................................................................................. 12.7-17.3 Nm (10-12 ft lbs) Windshield Wiper Linkage-to-Motor Bolt ................................................................................................................................. 14.8-20.2 Nm (11-14 ft lbs) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications > Page 12035 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications > Page 12036 Wiper Motor: Service and Repair REMOVAL 1. Remove the mounting arm and pivot shaft. 2. Disconnect the windshield wiper linkage. 1 Remove the bolt. 2 Disconnect the windshield wiper linkage. 3. Remove the windshield wiper motor. 1 Remove the bolts. 2 Remove the windshield wiper motor. INSTALLATION 1. To install, reverse the removal procedure. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Specifications Wiper Motor Linkage: Specifications Mounting Arm and Pivot Shaft Bolts .................................................................................................................................................. 7-9 Nm (63-80 in lbs) Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Specifications > Page 12040 Wiper Motor Linkage: Service and Repair REMOVAL NOTE: The windshield wiper pivot arms must be in the highest position to remove them. 1. Turn the ignition switch to the on position. 2. Turn the windshield wiper on. 3. Stop the windshield wiper pivot arms at the highest position by turning the ignition switch off. 4. Remove the windshield wiper pivot arm. 1 Remove the pivot arm nut cover. 2 Remove the nut. 3 Remove the windshield wiper pivot arm. 5. Raise and support the hood. 6. Remove the cowl grille seal. 7. Remove the LH cowl grille. 1 Remove the screw cover. 2 Remove the screws. 3 Remove the clips. 4 Remove the pin-type retainer. 5 Remove the LH cowl grille. NOTE: The two cowl grilles overlap at the center. The LH cowl grille must be removed first. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Specifications > Page 12041 8. Remove the RH cowl grille. 1 Remove the screw cover. 2 Remove the screws. 3 Remove the clips. 4 Remove the pin-type retainer. 5 Remove the RH cowl grille. 9. Remove the mounting arm and pivot shaft. 1 Disconnect the electrical connector. 2 Remove the bolts. 3 Remove the mounting arm and pivot shaft. INSTALLATION Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Specifications > Page 12042 1. To install, reverse the removal procedure. NOTE: Adjust the pivot arms. See: Wiper Arm/Adjustments Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay Wiper Relay: Locations Wiper High/Low Relay Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 12047 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 12048 Wiper Relay: Locations Wiper Run/Park Relay Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Wiper High/Low Relay > Page 12049 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 12050 Wiper Relay: Testing and Inspection Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 12051 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 12055 Wiper Switch: Diagrams Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 12056 Wiper Switch: Description and Operation The integrated multifunction switch is mounted to the LH side of the steering column and controls the turn signal, headlamp dimmer/flash-to-pass, windshield wiper/washer and hazard warning. The ignition switch is mounted below the steering column and is activated using the ignition key and rotating the key lock cylinder on the steering column. If equipped with manual transmission, the key release lever prevents rotation of the ignition cylinder to LOCK or ACC positions unless the lever is depressed. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis Wiper Switch: Flow of Diagnosis 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12059 Wiper Switch: Initial Inspection and Diagnostic Overview 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12060 Wiper Switch: Diagnostic Trouble Code Descriptions GEM/CTM Active Command Index Part 1 Of 2 Part 2 Of 2 GEM/CTM Diagnostic Trouble Code (DTC) Index Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12061 Part 1 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12062 Part 2 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12063 Part 3 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12064 Part 4 Of 4 GEM/CTM Parameter Identification (PID) Index Part 1 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12065 Part 2 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12066 Part 3 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12067 Wiper Switch: Symptom Related Diagnostic Procedures Part 1 Of 2 Part 2 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12068 Wiper Switch: Testing and Inspection Flow of Diagnosis 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures Initial Inspection and Diagnostic Overview Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12069 1. Verify the customer concern by operating the multifunction switch or ignition switch. 2. Visually inspect for obvious signs of mechanical and electrical damage. 3. If the concern remains after the inspection, connect the New Generation STAR (NGS) Tester to the Data Link Connector (DLC) located beneath the instrument panel and select the vehicle to be tested from the NGS tester menu. If NGS Tester does not communicate with the vehicle: ^ check that the program card is correctly installed. ^ check the connections to the vehicle. ^ check the ignition switch position. 4. If NGS Tester still does not communicate with the vehicle, refer to the New Generation STAR Tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS responds with: ^ CKT914, CKT915 or CKT70 = ALL ECUS NO RESP/NOT EQUIP, Diagnose the Module Communications Network. ^ NO RESP/NOT EQUIP for Generic Electronic Module (GEM) or Central Timer Module (CTM), go to Pinpoint Test A. See: Pinpoint Tests/Test A: No Communication With the GEM or CTM ^ SYSTEM PASSED, retrieve and record the continuous Diagnostic Trouble Codes (DTCs), erase the continuous DTCs and carry out self-test diagnostics for the GEM/CTM. 6. If the DTCs retrieved are related to the concern, go to the GEM/CTM Diagnostic Trouble Code (DTC) Index to continue diagnostics. See: Diagnostic Trouble Code Descriptions/GEM/CTM Diagnostic Trouble Code (DTC) Index 7. If no DTCs related to the concern are retrieved, proceed to Symptom Chart to continue diagnostics. See: Symptom Related Diagnostic Procedures GEM/CTM Active Command Index Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12070 Part 1 Of 2 Part 2 Of 2 GEM/CTM Diagnostic Trouble Code (DTC) Index Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12071 Part 1 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12072 Part 2 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12073 Part 3 Of 4 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12074 Part 4 Of 4 GEM/CTM Parameter Identification (PID) Index Part 1 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12075 Part 2 Of 3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12076 Part 3 Of 3 Symptom Related Diagnostic Procedures Part 1 Of 2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12077 Part 2 Of 2 Test A: No Communication With the GEM or CTM Test A1 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12078 Test A2 - A3 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12079 Test A4 - A5 Test B: Unable to Enter Self-Test Test B1 Test C: the Ignition Switch Is Inoperative Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12080 Test C1 Test D: No Power In ACC Test D1 Test E: No Power In Run Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12081 Test E1 Test E1 - E2 Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12082 Test F: No Power In Start Test F1 - F2 Component Tests and General Diagnostics Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12083 Component Testing Procedure Terminals Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Flow of Diagnosis > Page 12084 Schematic Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 12085 Wiper Switch: Service and Repair MULTIFUNCTION SWITCH Removal 1. Disconnect the battery ground cable. 2. Remove the ignition switch lock cylinder. 1. Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position. 2. Insert a punch through the hole in the lower steering column shroud and push the ignition switch lock cylinder release tab while pulling out the ignition switch lock cylinder 3. Twist the tilt wheel handle and shank and remove. 4. NOTE: Move gear selector to lowest position to access steering column opening cover. Release the four clips and remove the steering column opening cover. Ford F 150 4wd Pickup Workshop Manual (V8-5.4L SOHC VIN 3 (1999)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and Inspection > Page 12086 5. Remove the upper and lower steering column shrouds. 1. Remove the three screws. 2. Remove the lower steering column shroud. 3. Remove the upper steering column shroud. 6. Remove the mult1 function switch. 1. Remove the two screws. 2. Disconnect the electrical connectors. 3. Remove the mult1 function switch. Installation 1. NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy. To install, reverse the removal procedure.