Ford - E 150 Van - Workshop Manual - 1982 - 1982

Factory Workshop Manual Make Ford Model E 150 Van Engine and year V8-351 5.8L (1982) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 11 - 20, ( 12 13 14 15 16 17 18 19 ) > System Information > System Diagnosis Quick Test Service Codes 1-1 Through 4-4 (Tests Referred To Under Action To Take Are Pinpoint Tests) Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 21 - 30, ( 22 23 24 25 26 27 28 29 ) > System Information > System Diagnosis Quick Test Service Codes 1-1 Through 4-4 (Tests Referred To Under Action To Take Are Pinpoint Tests) Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 31 - 40, ( 32 33 34 35 36 37 38 39 ) > System Information > System Diagnosis Quick Test Service Codes 1-1 Through 4-4 (Tests Referred To Under Action To Take Are Pinpoint Tests) Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 41 - 50, ( 42 43 44 45 46 47 48 49 ) > System Information > System Diagnosis Quick Test Service Codes 1-1 Through 4-4 (Tests Referred To Under Action To Take Are Pinpoint Tests) Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations Power Door Lock Relay: Locations Lower LH Cowl Near Fuse Panel Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations Cruise Control Module: Locations LH Side Of I/P Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 25 Cruise Control Module: Testing and Inspection Use only a multi-meter of 5000 ohm/volt rating or higher when performing amplifier test. ``On'' Circuit Test 1. Turn ignition ``On.'' 2. Connect a voltmeter between light blue wire w/black hash and ground on models exc. 1983-87 Ranger, 1984-87 Bronco II and 1986-87 Aerostar or white wire w/purple stripe and ground on 1983-87 Ranger, 1984-87 Bronco II and 1986-87 Aerostar. 3. Battery voltage should be indicated when ``On'' switch on steering column is depressed and held. If battery voltage is not indicated, check horn relay and perform control switch test. 4. Release ``On'' button. Voltmeter should indicate 7.8 volts indicating ``On'' circuit is engaged. If voltage does not remain, check amplifier ground, fuses or circuit breakers or replace amplifier with known good amplifier and repeat test. 5. Replace as necessary. ``Off'' Circuit Test 1. Turn ignition ``On.'' 2. Connect a voltmeter between light blue wire w/black hash and ground. 3. Depress ``Off'' button. Voltage should drop to zero indicating ``On'' circuit is de-energized. 4. If voltage does not drop to zero, perform ``Control Switch Test.'' ``Set-Accelerate'' Circuit Test 1. Turn ignition ``On.'' 2. Connect a voltmeter between light blue wire w/black hash and ground. 3. Depress ``On'' switch, then hold ``Set-Accel'' button on steering wheel. Voltmeter should indicate 4.5 volts. Rotate steering wheel back and forth and check for voltmeter fluctuations. If reading varies more than .5 volts, perform ``Control Switch Test.'' ``Coast'' Circuit Test 1. Turn ignition ``On.'' 2. Connect a voltmeter between light blue wire w/black hash and ground. 3. Depress ``On'' switch, then depress and hold ``Coast'' button on steering wheel. Voltmeter should indicate 1.5 volts. Rotate steering wheel back and forth and check for voltage fluctuations. If reading varies more than .5 volts, perform ``Control Switch Test.'' ``Resume'' Circuit Test 1. Turn ignition ``On.'' 2. Connect a voltmeter between light blue wire w/black hash and ground. 3. Depress and hold ``Resume'' button. Voltmeter should indicate 6.5 volts. If all circuits are functioning properly, perform ``Servo Assembly Test'' using a known good amplifier. Do not replace amplifier before performing servo test. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Distance/Mileage Module > Component Information > Locations Fuel Distance/Mileage Module: Locations Near ECA Under RH Side Of I/P Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Horn Relay Location Under LH Side Of I/P. Under LH Side Of I/P, With Speed Control Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 34 Underneath LH Side Of I/P Below LH Side Of I/P Horn Relay With Speed Control Bronco F-150 thru F-350, E-150 thru E-350 and Super F Series The horn relay is use on vehicles equipped with speed control and is located under the left side of the instrument panel, left of the steering column and is mounted on the outboard attaching screw of the speed control amplifier module. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 35 Horn Relay: Testing and Inspection Fig. 3 Speed control wiring diagram. 1981---83 E-100-350 & 1984-87 E-150-350 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 36 Fig. 4 Speed control wiring diagram. 1981 F-100-350 & Bronco Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 37 Fig. 5 Speed control wiring diagram. 1982---83 F-100-350, 1984---87 F-150-350 & 1982---87 Bronco 1981-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986-87 Aerostar 1. Locate horn relay wire connector marked X and Y, Figs. 3, 4 and 5. 2. Using connector X, locate wire 460, then using a suitable voltmeter, check for battery voltage at male side of connector. 3. Using connector Y, locate wire 1, then using a suitable voltmeter, check for battery voltage at female side of connector. Depress horn, voltmeter should read zero and horn should sound. If battery voltage remains, circuit is open. Connectors should remain connected during testing. 4. Check horn relay by momentarily grounding circuit 1 to chassis. This bypasses horn switch and horn should sound. If horn does not sound, check for battery voltage at connector X wire 6 during relay operation. If voltage is present at circuit 6 during relay operation, an open circuit is indicated between horn and connector X. 5. If relay does not operate with battery voltage present at circuit 460 and circuit 1 is grounded, replace relay. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations Trailer Lighting Relay: Locations LH Rear Fender Below LH Taillight Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power Protection Relay > Component Information > Locations Power Protection Relay: Locations In Engine Compartment On LH Fender Apron Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations Engine Control Module: Locations LH Rear Of Engine Compartment LH Fender Apron Near Ignition Module Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 50 Engine Control Module: Description and Operation Fig. 7 Processor & calibration assembly The Electronic Control Assembly (ECA), Fig. 7, is the brain of the system. It is a solid state pre-programmed micro-computer which consists of a processor assembly and a calibration assembly, Fig. 7. The processor assembly contains the electronic circuitry which performs the following functions within a fraction of a second: a. Choose one of the sensor inputs for evaluation. b. Converts the input to a form usable by the computer to use that signal for calculations. c. Choose the proper operating strategy necessary for the operating conditions. d. Perform spark, EGR, air/fuel ratio, canister purge, throttle kicker and other calculations. e. Send electrical output control signals to the ignition module and control solenoids to adjust timing and dwell, EGR flow rate, thermactor air mode and throttle kicker mode. The processor assembly also contains a separate power supply which provides a continuous reference voltage of about 9 volts nominal to the sensors. The calibration assembly, Fig. 7, contains electronic circuitry which provides calibration equations necessary for specific vehicle application for use by the processor assembly, and provides adjustments for octane problems. The calibration assembly is mounted on the processor assembly. The power relay supplies battery voltage to the EEC system and is mounted on the right hand side of the ECA mounting bracket. It also protects the ECA from possible damage due to reversed polarity. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations RH Fender Apron w/EEC Attached To Top Of RH Fender Apron Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations RH Fender Apron w/EEC Attached To Top Of RH Fender Apron Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Description and Operation Ignition Control Module: Description and Operation Typical Ignition System The Ignition Module shuts off the primary circuit each time it receives a pulse from the magnetic pick-up Fig. 9. A timing circuit in the ignition module turns the primary current back on after a short period of time. High voltage is created each time the magnetic field is built up and collapsed. The red ignition module wire provides operating voltage for the module's electronic components in the Run mode. The white module wire and start bypass provide increased voltage for the module and coil during Start mode. Ignition Modules Dura Spark II systems with UIM (Universal Ignition Module) Fig. 10 can respond to another control signal from either an Ignition Barometric Pressure Switch, Ignition Timing Vacuum Switch, or the Microprocessor Control Unit (MCU), depending on the engine calibration. Responding to this second signal, the UIM provides additional spark timing control for certain operating conditions by shutting off the ignition coil current flow at a different time than with just the distributor pick-up signal. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Description and Operation > Page 62 Module Identification Chart For proper ignition module identification refer to Fig. 1. The modules are not interchangeable, Dura Spark II has 6 wire connector while Dura Spark III has a 5 wire connector. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations RH Fender Apron w/EEC On RH Fender Apron Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations Power Window Relay: Locations Lower LH Cowl Near Fuse Panel Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Wiper Control Module: Locations Upper LH Side Of I/P Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Radio Power Boost Switch > Component Information > Locations Radio Power Boost Switch: Locations Attached To RH Cowl Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Locations Brake Fluid Pressure Sensor/Switch: Locations Frame Wiring. On LH Frame At No. 2 Crossmember Applicable to: 138 Standard Van Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Top Of Parking Brake Assembly Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications TEMPERATURE SENSORS Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 92 Coolant Temperature Sensor/Switch (For Computer): Locations RH Side Of V8-302/5. Near Front Of RH Valve Cover Applicable to: 0L & V8-351/5.8L w/EEC Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 93 Coolant Temperature Sensor/Switch (For Computer): Description and Operation This sensor incorporates a thermistor in a brass housing with an integral wiring connector extending from the body. This sensor is installed in the heater outlet fitting of the intake manifold. The thermistor is a resistor whose resistance value is high at low temperatures and decreases as the temperature rises. The computer applies a voltage to the sensor and monitors the resultant voltage drop across the thermistor. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications Radiator Cooling Fan Temperature Sensor / Switch: Specifications Switch Torque Switch Torque Cooling Fan Switch 8-18 ft.lb Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Testing and Inspection Brake Switch (Cruise Control): Testing and Inspection Perform this test only when brake application will not disconnect the speed control system. 1. Check operation of stop lamps by applying approximately 6 lbs. of pressure to brake pedal. If more than 6 lbs. is required, check brake pedal actuation and stop lamp switch. 2. If stop lamps do not function properly, check bulbs, circuit fuse or stop lamp switch. 3. If stop lamps function properly, check for battery voltage at 6 way connector using black wire w/green stripe on 1980 models, 1981-83 E-100-350 and 1984-87 E-150-350 series, or white wire w/pink stripe on 1981-82 F-100-350 and Bronco series, or white wire w/purple stripe on 1983 F-100-350, Bronco and Ranger, 1984-87 F-150-350, Ranger, 1984-87 Bronco II and 1986-87 Aerostar. 4. Depress brake pedal until stop lamps are illuminated. Check voltage at red wire w/black stripe on 1980 models, 1981-83 E-100-350 and 1984-87 E-150-350 models, or the light green wire on 1981-83 F-100-350 and Bronco, 1984-87 F-150-350 and Bronco, 1983-87 Ranger, 1984-87 Bronco II and 1986-87 Aerostar. The difference between the two voltage readings must not exceed 1.5 volts. If voltage is greater, a high resistance exists in the circuit and must be found and corrected. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Service and Repair Clutch Switch: Service and Repair 1. Remove bracket mounting screw(s). 2. Disconnect electrical connector and remove switch and bracket assembly. 3. Remove switch from bracket. 4. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations Cruise Control Switch: Locations On Steering Wheel Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 107 Cruise Control Switch: Testing and Inspection 1980-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986 Aerostar Disconnect 6 way connector from control switch at the amplifier, then perform the following checks: 1. Connect a voltmeter between light blue-black hash lead and ground, then depress the ``On'' button and check for battery voltage. 2. Turn ignition ``Off,'' then connect an ohmmeter between light blue-black hash lead and ground. 3. Rotate steering wheel throughout its full range while making the following checks: a. Depress ``Off'' button and check for a reading of 0-1 ohm. b. Depress ``Set'' button and check for a reading of 646-714 ohms. c. Depress and hold ``Coast'' switch and check for a reading of 114-126 ohms. d. On models with ``Resume,'' depress and hold ``Resume'' switch and check for a reading of approximately 2200 ohms. 4. If resistance values are not as specified, inspect wiring, slip rings, turn signal copper brushes, speed control switch and steering column for proper ground. Check for proper ground by connecting an ohmmeter between upper steering column flange and a suitable ground. Resistance should be less then 1/2 ohm. Rotate steering wheel throughout its full range and ensure flexible coupling has a resistance of less than 1 ohm. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 108 Cruise Control Switch: Service and Repair 1. Remove steering wheel pad attaching screws from behind steering wheel. 2. While pulling pad away from steering wheel, disconnect horn and speed control wire connectors and remove pad. 3. Remove retaining nuts securing the speed control switches and trim plate retainer to the steering wheel pad. 4. Disconnect wiring connector on rear of steering wheel pad assembly, then remove switch and trim retainer assembly. 5. Remove speed control switches by snapping out of plastic retainer. 6. To remove the ground brush, remove steering wheel for access. 7. Snap the ground brush assembly out of the turn signal switch. 8. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Testing and Inspection Vehicle Speed Sensor/Transducer - Cruise Control: Testing and Inspection 1980-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986-87 Aerostar 1. Disconnect 6 way connector from amplifier assembly, then connect an ohmmeter between dark green wire w/white stripe and black wire on 1980 E-100-350, 1981-83 F-100-350 models and Bronco, and 1984-87 F-150-350 and Bronco, or green and black wire on 1980 F-100-350 and 1981-83 E-100-350 models and 1984-87 E-150-350 at the speed sensor end. A reading of 40 ohms should be obtained. A reading of 0 ohms indicates a shorted coil and an infinity reading indicates an open coil. 2. Replace sensor if a correct reading has not been obtained. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Switch <--> [Oil Pressure Sender] > Component Information > Locations Oil Pressure Switch: Locations LH Lower Front Of Engine Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Auxiliary Blower Switch Blower Motor Switch: Locations Auxiliary Blower Switch RH Side Of Function Control Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Auxiliary Blower Switch > Page 121 Blower Motor Switch: Locations Front Blower Switch LH Side Of Control Assembly Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations A/C EVAPORATOR DE-ICING SWITCH RH Dash Panel Attached To Evaporator Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations Door Switch: Locations Inside Driver's Door Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Top Of Parking Brake Assembly Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Automatic Transmission Backup Lamp Switch: Locations Automatic Transmission Attached To Base Of Steering Column Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Automatic Transmission > Page 137 Backup Lamp Switch: Locations Manual Transmission Attached To Shifter Assembly Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Automatic Transmission > Page 138 Backup Lamp Switch: Locations 3-Speed Manual Transmission Near Dash Panel Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations Top Of Brake Pedal Support Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 142 Brake Light Switch: Service and Repair Fig. 6 Stop light switch replacement. Exc. 1980---83 E-100 w/manual brakes. Fig. 7 Stop light switch replacement. 1980---83 E-100 w/manual brakes 1. Disconnect battery ground cable. 2. Disconnect electrical connector from switch, Figs. 6 and 7. 3. Remove hairpin retainer, then slide stop light switch, pushrod, nylon washers and bushings away from pedal and remove the switch from vehicle. 4. Reverse procedure to install. Ensure stop light switch wires are of sufficient length to allow full travel of the brake pedal. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations Door Switch: Locations Inside Driver's Door Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations Headlamp Dimmer Switch: Locations LH Floor Board Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair Headlamp Switch: Service and Repair Fig. 5 Light Switch E-100---350 1. Disconnect battery ground cable. 2. Remove knob and shaft assembly by depressing release button on switch housing and pulling straight out. 3. Remove bezel or mounting nut from switch, Fig. 4. 4. Disconnect electrical connector from switch and remove switch from vehicle. 5. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations Turn Signal Switch: Locations Upper LH Side Of Steering Column Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 155 Turn Signal Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove horn switch, then the steering wheel. 3. Remove turn signal switch lever by unscrewing from steering column. 4. On 1981---87 F-100---350 and Bronco models, remove lower steering column shroud. 5. On 1981---87 E-100---350 models, remove upper and lower steering column shrouds. 6. On all models, disconnect electrical connector from turn signal switch and remove switch attaching screws. 7. On all models with tilt column and 1980 E-100---350, F-100---350 and Bronco with fixed column, remove wires and terminals from steering column electrical connector, after noting color code and location of each connector. Remove plastic cover sleeve, if equipped, from wiring harness, then lift switch assembly out through top of column. On 1981---87 E-100---350 models equipped with tilt column and automatic transmission, disconnect transmission selector indicator light electrical connector from turn signal switch harness prior to removing the switch. 8. On all models with fixed column, except 1980 E-100---350, F-100---350 and Bronco, remove switch assembly by lifting out of column while guiding connector plug through opening in shift socket. On 1981---87 E-100---350 models equipped with fixed column and automatic transmission, remove transmission selector indicator light assembly with turn signal switch. 9. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Specifications MANIFOLD ABSOLUTE AND BAROMETRIC PRESSURE SENSORS Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Specifications > Page 161 Barometric Pressure Sensor: Locations In Engine Compartment On RH Fender Apron Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Specifications > Page 162 Barometric Pressure Sensor: Description and Operation Fig. 5 Barometric & manifold absolute pressure sensor These two sensors, Fig. 5, are combined into one unit. The BMAP sensor monitors the absolute value of the intake manifold pressure and atmospheric pressure (manifold absolute pressure is defined as barometric pressure minus manifold vacuum). Atmospheric pressure changes are converted into an electrical signal and fed to the computer for evaluation. From this input, the computer determines the EGR flow requirements depending on the altitude at which the vehicle is being operated. Intake manifold pressure changes are converted by a pressure-sensing element and electrical circuit by the computer. The signal is used by the computer to determine part throttle spark advance, EGR flow rate and air/fuel ratio. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Testing and Inspection > Barometric Pressure Sensor Barometric Pressure Sensor: Testing and Inspection Barometric Pressure Sensor 1. Disconnect switch from ignition module. 2. Connect suitable ohmmeter across switch terminals and compare resistance measured to values in chart. 3. Replace switch if resistance is not within specifications. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications TEMPERATURE SENSORS Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 168 Coolant Temperature Sensor/Switch (For Computer): Locations RH Side Of V8-302/5. Near Front Of RH Valve Cover Applicable to: 0L & V8-351/5.8L w/EEC Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 169 Coolant Temperature Sensor/Switch (For Computer): Description and Operation This sensor incorporates a thermistor in a brass housing with an integral wiring connector extending from the body. This sensor is installed in the heater outlet fitting of the intake manifold. The thermistor is a resistor whose resistance value is high at low temperatures and decreases as the temperature rises. The computer applies a voltage to the sensor and monitors the resultant voltage drop across the thermistor. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications CRANKSHAFT SENSOR Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 173 Crankshaft Position Sensor: Locations RH Front Of Engine Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 174 Crankshaft Position Sensor: Description and Operation Fig.6 - Crankshaft Position Sensor Fig.7 - Crankshaft Position Sensor DESCRIPTION The crankshaft vibration damper is fitted with a four-lobe "pulse ring" which provides the system with an accurate indication of when the pistons reach 10 BTDC. This indication is called the reference timing. Figs. 6 and 7. The pulse ring is a powdered metal ring positioned on the crankshaft vibration damper during manufacture. It has four equally spaced lobes which represent crankshaft position when the pistons reach 10 BTDC. During operation, the lobes on the pulse ring pass by the tip of the CP sensor. The pulse ring interrupts the magnetic field at the tip of the sensor. When the field is interrupted, an output signal is generated and sent to the ECA. As the crankshaft turns, the ECA evaluates the electrical impulses to determine the exact position of the crankshaft at any given time. By the frequency of the impulses, the ECA can determine the engine speed. With these two factors, the ECA will determine the appropriate ignition timing advance required for best engine operation. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Locations EGR Valve Position Sensor: Locations LH Side Of V8-302/5. At Center Engine To Rear Of Carburetor Applicable to: 0L Engine Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Locations > Page 178 EGR Valve Position Sensor: Description and Operation Fig. 6 EGR valve position sensor This sensor, Fig. 6, is used to monitor the EGR valve pintle position. The computer applies a reference voltage to the EVP sensor, and the resulting signal from the EVP sensor is proportional to the amount of exhaust gases flowing through the EGR valve pintle into the intake manifold. Depending on the input from this and other sensors, the computer can increase or decrease EGR flow by activating or deactivating a pair of solenoid vacuum valves. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications TEMPERATURE SENSORS Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 182 Intake Air Temperature Sensor: Description and Operation DESCRIPTION This sensor is used on models with fuel injection. It sends air temperature information to the Electronic Control Unit to make changes for air temperature variations. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Component Testing Intake Air Temperature Sensor: Testing and Inspection Component Testing NOTE: Prior to performing any test on this system, insure that temperature switch is above 65° F. 1. Disconnect connector from wiring harness. 2. Connect an ohmmeter or self-powered test light to temperature switch connector terminals. 3. Cool the switch to below 40° F by spraying with Refrigerant 12. CAUTION: Do not spray refrigerant with engine running, as any refrigerant drawn into the carburetor and burned in the engine will produce poisonous phosgene gas. Conduct this procedure in well ventilated area. 4. When switch is cooled below 40° F. a. On type 1 switches, the internal switch contacts should open. The ohmmeter should read maximum resistance or the test light should be off. If switch does not open below 40° F, replace switch. b. On type 2 switches, the internal switch contacts should close. The ohmmeter should read zero resistance and the test light should be on. If test light does not go on or ohmmeter indicates a resistance of 1 ohm or more, replace switch. 5. Increase switch temperature to above 70° F by placing palm of hand on metal surface of switch or by starting engine and allowing the exhaust manifold heat to increase the intake air temperature. 6. When switch temperature is above 70° F. a. On type 1 switches, the internal switch contacts should close. The ohmmeter should read zero resistance and the test light should be on. If test light does not go on or ohmmeter indicates a resistance of 1 ohm or more, replace switch. b. On type 2 switches, the internal switch contacts should open. The ohmmeter should read maximum resistance or the test light should be off. If switch does not open, replace switch. c. If switch is replaced, check operation of new switch before connecting harness connector. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation Knock Sensor: Description and Operation Knock Sensor The knock sensor, Fig. 11, is a piezo-electric accelerator accelerometer with the sensor designed to resonate at approximately the same frequency as the engine knock frequency.. The sensor uses the resonant frequency to mechanically amplify the engine knock frequency (5-6 KHz). This method allows relatively large signals to be achieved without electrical amplification. The sensor has a thin circular piezoelectric ceramic disk which is bonded to a metal diaphragm. Electrical connections are made through a two-pin integral connector. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Testing and Inspection > Component Testing Knock Sensor: Testing and Inspection Component Testing Fig.8 - MCU System Wiring Circuit 1. Make sure that the following three steps are properly conducted in order to simulate spark knock conditions and determine that spark detection system is inoperative. If not, repeat test to verify problem. a. Make sure that engine is at normal operating temperature. Run engine at 2000 rpm for 2 minutes, then turn key off. Immediately restart engine and allow to idle. b. Observe voltmeter and vacuum gauge for initialization pulses after restarting the engine. The throttle kicker will also extend (increase engine speed) and remain on throughout the test. c. On vehicles with spark knock sensor, when initial pulses occur, immediately simulate spark knock by placing a 3/8 inch extension on manifold near base of knock sensor. Tap end of extension with a small hammer for about 15 seconds. 2. Disconnect jumper wire from self-test trigger input circuit 201. 3. With ignition key off, disconnect vehicle harness from spark knock sensor. 4. Using a torque wrench and a 1 1/8 inch deep socket, make sure that spark sensor is torqued to 12-18 ft. lbs. If sensor is properly torqued, proceed to next step. If not, torque to specifications. 5. Disconnect vehicle harness from MCU and spark sensor. Connect one lead of an ohmmeter to circuit 310 of vehicle harness and other lead to engine block, Fig. 8. If resistance is 1000 ohms or more, proceed to next step. If resistance is less than 1000 ohms, repair short to ground in circuit 301. 6. With key off and knock sensor harness disconnected, check circuit 310 of vehicle harness for continuity. If resistance is 10 ohms or less, continue to next step. If resistance is greater than 10 ohms, repair circuit 310. 7. Check circuit 60 of vehicle harness for continuity between knock sensor and MCU, Fig. 8. If resistance is 10 ohms or less, reconnect harness connector to MCU and proceed to next step. If resistance is greater than 10 ohms, service circuit 60. 8. Reconnect jumper wire to circuits 201 and 60 of VIP connector, Fig. 8. 9. Connect a test lamp to positive terminal of battery, then disconnect knock sensor from vehicle harness. 10. Perform "Engine Running Functional Test" procedure. When the four initialization pulses occur, continuously tap circuit 310 of the vehicle harness connector, which mates to the knock sensor connector, with the probe end for 5 seconds while observing voltmeter pulses. If a code 25 is Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Testing and Inspection > Component Testing > Page 190 observed, replace MCU. If any other code is observed, replace spark knock sensor. SPARK KNOCK, ONLY AT WIDE OPEN THROTTLE AND/OR POOR PERFORMANCE/MILEAGE 1. If engine has a spark knock sensor, disconnect it. 2. Make sure that ignition timing is within specifications. 3. With engine running at normal operating temperature, disconnect the two wire ignition module connector (yellow wire is circuit 324 and black/white wire is circuit 69) from vehicle harness. Using a jumper wire, jump the wires together at the ignition module and note ignition timing. Remove jumper wire and note ignition timing. If timing retards 16-20 degrees, reconnect ignition module and proceed to next step. If timing does not retard 16-20 degrees, replace ignition module and repeat steps 1, 2 and 3. 4. With engine at normal operating temperature, set high cam on lowest step that will maintain engine speed greater than 1200 rpm. Note ignition timing, then disconnect and plug vacuum hose from zone vacuum switch and again note timing. If timing retards more than 5 degrees, on engines with spark knock sensor, proceed to step 6, on all other engines MCU system is okay. If timing does not retard more than 5 degrees, proceed to next step. 5. With engine still at 1200 rpm, disconnect ignition module (connector with yellow and black/white wires). If timing retards, check circuit 324 for short to ground. If circuit is okay, replace MCU unit and retest. If timing does not retard, check circuit 324 for open circuit. If circuit is okay, Replace MCU unit and retest. 6. On engines with spark knock sensor, reconnect sensor. Repeat Engine Running Functional Test, but do not simulate knock by taping sensor. If service code 25 appears, MCU system is okay, testing is completed. If any other service code appears, replace knock sensor and retest. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications MANIFOLD ABSOLUTE AND BAROMETRIC PRESSURE SENSORS Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 194 Manifold Pressure/Vacuum Sensor: Locations RH Fender Apron w/EEC In Engine Compartment On RH Fender Apron Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 195 Manifold Pressure/Vacuum Sensor: Description and Operation Fig. 5 Barometric & manifold absolute pressure sensor DESCRIPTION These two sensors, Fig. 5, are combined into one unit. The BMAP sensor monitors the absolute value of the intake manifold pressure and atmospheric pressure (manifold absolute pressure is defined as barometric pressure minus manifold vacuum). Atmospheric pressure changes are converted into an electrical signal and fed to the computer for evaluation. From this input, the computer determines the EGR flow requirements depending on the altitude at which the vehicle is being operated. Intake manifold pressure changes are converted by a pressure-sensing element and electrical circuit by the computer. The signal is used by the computer to determine part throttle spark advance, EGR flow rate and air/fuel ratio. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Gas Oxygen (EGO) Sensor <--> [Oxygen Sensor] > Component Information > Locations Exhaust Gas Oxygen (EGO) Sensor: Locations RH Side Of V8-302/5. On Exhaust Manifold RH Side Of Engine Applicable to: 0L & V8-351/5.8L w/EEC Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Gas Oxygen (EGO) Sensor <--> [Oxygen Sensor] > Component Information > Locations > Page 199 Exhaust Gas Oxygen (EGO) Sensor: Description and Operation Fig. 4 Exhaust gas oxygen sensor This sensor, Fig. 4, is installed in the exhaust manifold and provides information to the ECA as to the oxygen content of the exhaust gases. It monitors the oxygen content of the exhaust gases and generates an output of .6 to 1.0 volt when detecting a rich exhaust gas mixture (absence of oxygen) and less than .2 volts when detecting a lean mixture (presence of oxygen). This constantly changing voltage signal is sent to the ECA for analysis. The outer surface of the sensor is a threaded steel housing and shell. The sensor body is protected by a shield pressed into the housing where it projects into the exhaust manifold. Exhaust gases contact the sensor body by entering through flutes in the sensor shield. A vent is provided in the shell to allow atmospheric air to enter the inner portion of the sensor body. The sensor connects to the vehicle wiring harness with a connector that is attached to the inner (positive) terminal. The shell is the negative terminal of the sensor and provides the return signal path through the engine block. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications THROTTLE POSITION SENSOR SPECIFICATIONS Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 203 Throttle Position Sensor: Description and Operation Fig. 2 Throttle position sensor (typical) This sensor, Fig. 2, is basically a rheostat switch attached to the carburetor throttle shaft and responds to throttle valve angle changes. The throttle angles are classified into three operating modes as follows: a. Closed Throttle (Idle or Deceleration) b. Part Throttle c. Wide Open Throttle (Maximum Acceleration) The ECA applies a reference voltage of about 9 volts to the sensor. The resultant sensor voltage supplied to the ECA, which is determined by the throttle position, is used by the ECA to determine the proper amount of spark advance, EGR flow, air/fuel ratio and thermactor air mode. The throttle position sensor mounting holes are slotted to permit adjustment. If the sensor is replaced, it must be correctly positioned or incorrect throttle information will be sent to the ECA. The adjustment requires use of special electronic test equipment. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 204 Throttle Position Sensor: Adjustments Engines with EEC III Turn ignition to RUN position and remove vacuum hose from throttle kicker, as equipped. With engine not running, compare voltage reading against specifications and adjust as needed. Engines with EEC IV Connect positive probe of DVOM along terminal C (lower) of TPS and connect negative probe along terminal A (upper). Turn ignition on but do not start vehicle. Adjust TPS to specified value. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations At LH Side Of Dash Panel Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Speed Sensor Test Vehicle Speed Sensor: Testing and Inspection Speed Sensor Test 1980-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986-87 Aerostar 1. Disconnect 6 way connector from amplifier assembly, then connect an ohmmeter between dark green wire w/white stripe and black wire on 1980 E-100-350, 1981-83 F-100-350 models and Bronco, and 1984-87 F-150-350 and Bronco, or green and black wire on 1980 F-100-350 and 1981-83 E-100-350 models and 1984-87 E-150-350 at the speed sensor end. A reading of 40 ohms should be obtained. A reading of 0 ohms indicates a shorted coil and an infinity reading indicates an open coil. 2. Replace sensor if a correct reading has not been obtained. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Page 210 Vehicle Speed Sensor: Service and Repair 1. Separate electrical connector leading to the amplifier assembly. 2. Disconnect upper and lower speedometer cables at the speed sensor. Remove speed sensor. 3. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Locations EGR Valve Position Sensor: Locations LH Side Of V8-302/5. At Center Engine To Rear Of Carburetor Applicable to: 0L Engine Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Locations > Page 215 EGR Valve Position Sensor: Description and Operation Fig. 6 EGR valve position sensor This sensor, Fig. 6, is used to monitor the EGR valve pintle position. The computer applies a reference voltage to the EVP sensor, and the resulting signal from the EVP sensor is proportional to the amount of exhaust gases flowing through the EGR valve pintle into the intake manifold. Depending on the input from this and other sensors, the computer can increase or decrease EGR flow by activating or deactivating a pair of solenoid vacuum valves. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Tank Selector Switch > Component Information > Locations Fuel Tank Selector Switch: Locations LH Side Of I/P Near Fuse Panel Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pump Inertia Switch: > 831112S > Sep > 84 > Fuel System - Stalls/No Start/Hesitation/ Stumble Fuel Pump Inertia Switch: Customer Interest Fuel System - Stalls/No Start/Hesitation/ Stumble Article No. 83-11-12-S STALLS/NO START/HESITATION/ STUMBLE - VAPOR LOCK (5.8L, 6.6L 7.5L) - VEHICLES OVER 8500 LBS. GVW LIGHT TRUCKS 1980/82 E250/350, F250/350 The service part numbers for kits "D" and "E" have been changed from E2UZ-9350-B to E0UZ-9350-D (Kit D) and E2UZ-9350-C to E0UZ-9350-C (Kit E) in TSB 83-11-12. The TSB Article is being reprinted showing the correct part numbers. NOTE: This TSB replaces TSB 82-14-21 dated July 16, 1982 in its entirety. DO NOT attempt to use TSB 82-14-21 to order service parts. Loss of road speed, hesitation, or engine stall on the subject vehicles operated at ambient temperatures over 85~F or at elevations over 4,500 feet, may be the result of fuel vaporization. A modification kit is available for vehicles experiencing this condition. It consists of an in-tank fuel pump, inertia shut-off switch, motorized fuel selector valve, vapor separator, and a vapor return system, along with related fuel lines and electrical wiring and devices. Before this modification is considered, other factors that could result in the same symptoms should be evaluated. Some of these include: ^ Plugged fuel filter at carburetor or tank. ^ Restricted fuel line. ^ Contaminated or low quality fuel. ^ Malfunctioning fuel pump or carburetor. If it is determined that the above factors have not caused the customer concern then the appropriate modification kit should be used to change the fuel system. Hardware Required: Components required to modify the vehicle differ with vehicle series, engine model and type of fuel tank. These have been packaged into 13 different kits. The chart that follows describes the specific kits that are required for the various vehicle configurations. Continued on next page TANK ENGINE (CID) KITS REQUIRED F-Series Single (Midship) 351M/400 A, F, H Single (Plastic Aft Axle) 351M/400 F, C, L Single (Metal Aft Axle) 351M/400 B, F, L Dual (Steel Aft Axle) 351M/400 A, B, F, I Dual (Plastic Aft Axle) 351M/400 A, C, F, I E-Series Single (Aft Axle) 351M/400 D, F, J Dual 351M/400 D, E, F, K E-Series Single (Aft Axle) 7.5L 460 D, G, J Dual 7.5L 460 D, E, G, K KIT SERVICE PART NO. DESCRIPTION CLASS A E2TZ-9350-D Fuel Pump/Sender Kit CG B E2TZ-9350-F Fuel Pump/Sender Kit CG C E2TZ-9350-C Fuel Pump/Sender Kit CG D E0UZ-9350-D Fuel Pump/Sender Kit CG E E0UZ-9350-C Fuel Pump/Sender Kit CG F E0TZ-9B328-A Vapor Separator Kit CG G E0TZ-9B328-B Vapor Separator Kit CG H E2TZ-9A350-H Fuel Line/Electrical Kit CG I E2TZ-9A350-F Fuel Line/Electrical Kit CG J E2UZ-9A350-F Fuel Line/Electrical Kit CG K E2UZ-9A350-D Fuel Line/Electrical Kit CG L E2TZ-9350-G Fuel Line/Electrical Kit CG Select the appropriate kit required; the detailed installation instructions will be supplied with each kit. OTHER APPLICABLE ARTICLES: 83-11-12 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pump Inertia Switch: > 831112S > Sep > 84 > Fuel System - Stalls/No Start/Hesitation/ Stumble > Page 228 ARTICLES SUPERSEDED: 82-14-21; 83-11-23 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. DLR. CODING: Basic Part No. 9237 Code: H6 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pump Inertia Switch: > 831112S > Sep > 84 > Fuel System - Stalls/No Start/Hesitation/ Stumble Fuel Pump Inertia Switch: All Technical Service Bulletins Fuel System - Stalls/No Start/Hesitation/ Stumble Article No. 83-11-12-S STALLS/NO START/HESITATION/ STUMBLE - VAPOR LOCK (5.8L, 6.6L 7.5L) - VEHICLES OVER 8500 LBS. GVW LIGHT TRUCKS 1980/82 E250/350, F250/350 The service part numbers for kits "D" and "E" have been changed from E2UZ-9350-B to E0UZ-9350-D (Kit D) and E2UZ-9350-C to E0UZ-9350-C (Kit E) in TSB 83-11-12. The TSB Article is being reprinted showing the correct part numbers. NOTE: This TSB replaces TSB 82-14-21 dated July 16, 1982 in its entirety. DO NOT attempt to use TSB 82-14-21 to order service parts. Loss of road speed, hesitation, or engine stall on the subject vehicles operated at ambient temperatures over 85~F or at elevations over 4,500 feet, may be the result of fuel vaporization. A modification kit is available for vehicles experiencing this condition. It consists of an in-tank fuel pump, inertia shut-off switch, motorized fuel selector valve, vapor separator, and a vapor return system, along with related fuel lines and electrical wiring and devices. Before this modification is considered, other factors that could result in the same symptoms should be evaluated. Some of these include: ^ Plugged fuel filter at carburetor or tank. ^ Restricted fuel line. ^ Contaminated or low quality fuel. ^ Malfunctioning fuel pump or carburetor. If it is determined that the above factors have not caused the customer concern then the appropriate modification kit should be used to change the fuel system. Hardware Required: Components required to modify the vehicle differ with vehicle series, engine model and type of fuel tank. These have been packaged into 13 different kits. The chart that follows describes the specific kits that are required for the various vehicle configurations. Continued on next page TANK ENGINE (CID) KITS REQUIRED F-Series Single (Midship) 351M/400 A, F, H Single (Plastic Aft Axle) 351M/400 F, C, L Single (Metal Aft Axle) 351M/400 B, F, L Dual (Steel Aft Axle) 351M/400 A, B, F, I Dual (Plastic Aft Axle) 351M/400 A, C, F, I E-Series Single (Aft Axle) 351M/400 D, F, J Dual 351M/400 D, E, F, K E-Series Single (Aft Axle) 7.5L 460 D, G, J Dual 7.5L 460 D, E, G, K KIT SERVICE PART NO. DESCRIPTION CLASS A E2TZ-9350-D Fuel Pump/Sender Kit CG B E2TZ-9350-F Fuel Pump/Sender Kit CG C E2TZ-9350-C Fuel Pump/Sender Kit CG D E0UZ-9350-D Fuel Pump/Sender Kit CG E E0UZ-9350-C Fuel Pump/Sender Kit CG F E0TZ-9B328-A Vapor Separator Kit CG G E0TZ-9B328-B Vapor Separator Kit CG H E2TZ-9A350-H Fuel Line/Electrical Kit CG I E2TZ-9A350-F Fuel Line/Electrical Kit CG J E2UZ-9A350-F Fuel Line/Electrical Kit CG K E2UZ-9A350-D Fuel Line/Electrical Kit CG L E2TZ-9350-G Fuel Line/Electrical Kit CG Select the appropriate kit required; the detailed installation instructions will be supplied with each kit. OTHER APPLICABLE ARTICLES: 83-11-12 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pump Inertia Switch: > 831112S > Sep > 84 > Fuel System - Stalls/No Start/Hesitation/ Stumble > Page 234 ARTICLES SUPERSEDED: 82-14-21; 83-11-23 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. DLR. CODING: Basic Part No. 9237 Code: H6 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications THROTTLE POSITION SENSOR SPECIFICATIONS Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 238 Throttle Position Sensor: Description and Operation Fig. 2 Throttle position sensor (typical) This sensor, Fig. 2, is basically a rheostat switch attached to the carburetor throttle shaft and responds to throttle valve angle changes. The throttle angles are classified into three operating modes as follows: a. Closed Throttle (Idle or Deceleration) b. Part Throttle c. Wide Open Throttle (Maximum Acceleration) The ECA applies a reference voltage of about 9 volts to the sensor. The resultant sensor voltage supplied to the ECA, which is determined by the throttle position, is used by the ECA to determine the proper amount of spark advance, EGR flow, air/fuel ratio and thermactor air mode. The throttle position sensor mounting holes are slotted to permit adjustment. If the sensor is replaced, it must be correctly positioned or incorrect throttle information will be sent to the ECA. The adjustment requires use of special electronic test equipment. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 239 Throttle Position Sensor: Adjustments Engines with EEC III Turn ignition to RUN position and remove vacuum hose from throttle kicker, as equipped. With engine not running, compare voltage reading against specifications and adjust as needed. Engines with EEC IV Connect positive probe of DVOM along terminal C (lower) of TPS and connect negative probe along terminal A (upper). Turn ignition on but do not start vehicle. Adjust TPS to specified value. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications CRANKSHAFT SENSOR Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 244 Crankshaft Position Sensor: Locations RH Front Of Engine Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 245 Crankshaft Position Sensor: Description and Operation Fig.6 - Crankshaft Position Sensor Fig.7 - Crankshaft Position Sensor DESCRIPTION The crankshaft vibration damper is fitted with a four-lobe "pulse ring" which provides the system with an accurate indication of when the pistons reach 10 BTDC. This indication is called the reference timing. Figs. 6 and 7. The pulse ring is a powdered metal ring positioned on the crankshaft vibration damper during manufacture. It has four equally spaced lobes which represent crankshaft position when the pistons reach 10 BTDC. During operation, the lobes on the pulse ring pass by the tip of the CP sensor. The pulse ring interrupts the magnetic field at the tip of the sensor. When the field is interrupted, an output signal is generated and sent to the ECA. As the crankshaft turns, the ECA evaluates the electrical impulses to determine the exact position of the crankshaft at any given time. By the frequency of the impulses, the ECA can determine the engine speed. With these two factors, the ECA will determine the appropriate ignition timing advance required for best engine operation. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Service and Repair Ignition Switch: Service and Repair Fig. 3 Ignition switch replacement 1. Disconnect battery ground cable. 2. Remove steering column shroud and lower the steering column. 3. Disconnect electrical connector from switch, then remove 2 switch attaching nuts. 4. Lift switch up to disengage actuator rod, then remove switch from vehicle, Fig. 3. 5. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation Knock Sensor: Description and Operation Knock Sensor The knock sensor, Fig. 11, is a piezo-electric accelerator accelerometer with the sensor designed to resonate at approximately the same frequency as the engine knock frequency.. The sensor uses the resonant frequency to mechanically amplify the engine knock frequency (5-6 KHz). This method allows relatively large signals to be achieved without electrical amplification. The sensor has a thin circular piezoelectric ceramic disk which is bonded to a metal diaphragm. Electrical connections are made through a two-pin integral connector. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Testing and Inspection > Component Testing Knock Sensor: Testing and Inspection Component Testing Fig.8 - MCU System Wiring Circuit 1. Make sure that the following three steps are properly conducted in order to simulate spark knock conditions and determine that spark detection system is inoperative. If not, repeat test to verify problem. a. Make sure that engine is at normal operating temperature. Run engine at 2000 rpm for 2 minutes, then turn key off. Immediately restart engine and allow to idle. b. Observe voltmeter and vacuum gauge for initialization pulses after restarting the engine. The throttle kicker will also extend (increase engine speed) and remain on throughout the test. c. On vehicles with spark knock sensor, when initial pulses occur, immediately simulate spark knock by placing a 3/8 inch extension on manifold near base of knock sensor. Tap end of extension with a small hammer for about 15 seconds. 2. Disconnect jumper wire from self-test trigger input circuit 201. 3. With ignition key off, disconnect vehicle harness from spark knock sensor. 4. Using a torque wrench and a 1 1/8 inch deep socket, make sure that spark sensor is torqued to 12-18 ft. lbs. If sensor is properly torqued, proceed to next step. If not, torque to specifications. 5. Disconnect vehicle harness from MCU and spark sensor. Connect one lead of an ohmmeter to circuit 310 of vehicle harness and other lead to engine block, Fig. 8. If resistance is 1000 ohms or more, proceed to next step. If resistance is less than 1000 ohms, repair short to ground in circuit 301. 6. With key off and knock sensor harness disconnected, check circuit 310 of vehicle harness for continuity. If resistance is 10 ohms or less, continue to next step. If resistance is greater than 10 ohms, repair circuit 310. 7. Check circuit 60 of vehicle harness for continuity between knock sensor and MCU, Fig. 8. If resistance is 10 ohms or less, reconnect harness connector to MCU and proceed to next step. If resistance is greater than 10 ohms, service circuit 60. 8. Reconnect jumper wire to circuits 201 and 60 of VIP connector, Fig. 8. 9. Connect a test lamp to positive terminal of battery, then disconnect knock sensor from vehicle harness. 10. Perform "Engine Running Functional Test" procedure. When the four initialization pulses occur, continuously tap circuit 310 of the vehicle harness connector, which mates to the knock sensor connector, with the probe end for 5 seconds while observing voltmeter pulses. If a code 25 is Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Testing and Inspection > Component Testing > Page 254 observed, replace MCU. If any other code is observed, replace spark knock sensor. SPARK KNOCK, ONLY AT WIDE OPEN THROTTLE AND/OR POOR PERFORMANCE/MILEAGE 1. If engine has a spark knock sensor, disconnect it. 2. Make sure that ignition timing is within specifications. 3. With engine running at normal operating temperature, disconnect the two wire ignition module connector (yellow wire is circuit 324 and black/white wire is circuit 69) from vehicle harness. Using a jumper wire, jump the wires together at the ignition module and note ignition timing. Remove jumper wire and note ignition timing. If timing retards 16-20 degrees, reconnect ignition module and proceed to next step. If timing does not retard 16-20 degrees, replace ignition module and repeat steps 1, 2 and 3. 4. With engine at normal operating temperature, set high cam on lowest step that will maintain engine speed greater than 1200 rpm. Note ignition timing, then disconnect and plug vacuum hose from zone vacuum switch and again note timing. If timing retards more than 5 degrees, on engines with spark knock sensor, proceed to step 6, on all other engines MCU system is okay. If timing does not retard more than 5 degrees, proceed to next step. 5. With engine still at 1200 rpm, disconnect ignition module (connector with yellow and black/white wires). If timing retards, check circuit 324 for short to ground. If circuit is okay, replace MCU unit and retest. If timing does not retard, check circuit 324 for open circuit. If circuit is okay, Replace MCU unit and retest. 6. On engines with spark knock sensor, reconnect sensor. Repeat Engine Running Functional Test, but do not simulate knock by taping sensor. If service code 25 appears, MCU system is okay, testing is completed. If any other service code appears, replace knock sensor and retest. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Switch: Locations Part Of Driver's Seat Belt Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Pedal Position Switch <--> [Clutch Switch] > Component Information > Testing and Inspection Clutch Pedal Position Switch: Testing and Inspection Manual Transmission Vehicles Only This switch functions magnetically. Do not use magnetized tools near this switch. 1. If the switch is open when the clutch pedal is released, speed control will not operate. This must be corrected before making any other tests. Use only a multimeter of 5000 ohm/volt rating or higher when performing the clutch switch test. 2. Disconnect switch pigtail connector from speed control harness connector and connect an ohmmeter to the two switch connector terminals. 3. With clutch pedal in the fully released position, the resistance should be less than 5 ohms. With clutch pedal fully depressed, the circuit should be open. 4. If switch does not function as described, remove and replace switch. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Service and Repair Ignition Switch: Service and Repair Fig. 3 Ignition switch replacement 1. Disconnect battery ground cable. 2. Remove steering column shroud and lower the steering column. 3. Disconnect electrical connector from switch, then remove 2 switch attaching nuts. 4. Lift switch up to disengage actuator rod, then remove switch from vehicle, Fig. 3. 5. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Location For C6 Transmission Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 269 Neutral Safety Switch: Service and Repair Fig. 8 Neutral safety switch replacement. Exc. automatic overdrive transmission EXC. AUTOMATIC OVERDRIVE TRANSMISSION 1. Disconnect battery ground cable. 2. Remove downshift linkage rod return spring from low-reverse servo cover. 3. Apply penetrating oil to outer lever attaching nut, then remove transmission downshift outer lever attaching nut and lever. 4. Remove neutral safety switch attaching bolts, then disconnect electrical connectors and remove switch from vehicle. 5. To install, position switch on transmission and secure with attaching bolts. Do not tighten bolts at this time. 6. Place transmission manual lever in neutral position, then insert a .091 inch gauge pin through gauge pin holes, Fig. 8. 7. Tighten switch attaching bolts, then remove gauge pin. 8. Install outer downshift lever and retaining nut. 9. Install downshift linkage rod return spring between lever and retaining clip on low-reverse servo cover. 10. Reconnect electrical connectors, then check operation of switch. W/AUTOMATIC OVERDRIVE TRANSMISSION 1. Disconnect battery ground cable. 2. Raise and support vehicle. 3. Disconnect electrical connector at neutral safety switch, lifting connector straight up. 4. Using suitable socket, remove neutral safety switch and O-ring seal. 5. Reverse procedure to install, installing new O-ring seal. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Technical Service Bulletins > Customer Interest: > 84219 > Oct > 84 > Wiper/Washer - Low Fluid Warning Light Stays On Washer Fluid Level Switch: Customer Interest Wiper/Washer - Low Fluid Warning Light Stays On Article No. 84-21-9 WIPER/WASHER - LOW FLUID WARNING LIGHT STAYS ON FORD ALL MODEL YEARS AND ALL CAR LINES WITH LOW FLUID WARNING LIGHT LINCOLN-MERCURY ALL MODEL YEARS AND ALL CAR LINES WITH LOW FLUID WARNING LIGHT LIGHT TRUCKS ALL MODEL YEARS AND ALL LINES WITH LOW FLUID WARNING LIGHT On some vehicles equipped with low fluid warning light, the light may stay on even when the washer reservoir is full. This is caused by using washer fluid concentrate (C9AZ-19550-A/B) that has not been mixed with water according to the instructions. The undiluted washer solution is absorbed by the float resulting in the float sinking. When filling the washer reservoir with washer fluid concentrate (C9AZ-19550-A/B), the instructions on the can must be followed. Mixing the concentrated washer fluid with water will stop the float from sinking. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 84219 > Oct > 84 > Wiper/Washer - Low Fluid Warning Light Stays On Washer Fluid Level Switch: All Technical Service Bulletins Wiper/Washer - Low Fluid Warning Light Stays On Article No. 84-21-9 WIPER/WASHER - LOW FLUID WARNING LIGHT STAYS ON FORD ALL MODEL YEARS AND ALL CAR LINES WITH LOW FLUID WARNING LIGHT LINCOLN-MERCURY ALL MODEL YEARS AND ALL CAR LINES WITH LOW FLUID WARNING LIGHT LIGHT TRUCKS ALL MODEL YEARS AND ALL LINES WITH LOW FLUID WARNING LIGHT On some vehicles equipped with low fluid warning light, the light may stay on even when the washer reservoir is full. This is caused by using washer fluid concentrate (C9AZ-19550-A/B) that has not been mixed with water according to the instructions. The undiluted washer solution is absorbed by the float resulting in the float sinking. When filling the washer reservoir with washer fluid concentrate (C9AZ-19550-A/B), the instructions on the can must be followed. Mixing the concentrated washer fluid with water will stop the float from sinking. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Washer Fluid Level Switch: > 841628 > Jul > 84 > Brakes (Rear) - Accelerated Wear Brake Shoe: All Technical Service Bulletins Brakes (Rear) - Accelerated Wear Articles No. 84-16-28 BRAKE, REAR - ACCELERATED WEAR - VEHICLES WITH 11" DIAMETER REAR BRAKES LIGHT TRUCKS 1975-84 E & F-100/150 & BRONCO This article supersedes TSB article 83-25-18, dated December 13, 1983, to include all 1975-84 E & F-100/150 & Bronco vehicles that have 11" diameter rear brakes. Some E and F-100/150 and Bronco vehicles subjected to extreme duty cycles in urban delivery/service operations may experience accelerated rear brake wear. A service kit(E0UZ-2C178-A) has been released for these vehicles and should be installed in its entirety if the vehicle exhibits any of the following conditions: ^ Side to side imbalance in rear braking effectiveness. ^ Side to side imbalance in rear brake lining wear. ^ Excessive heat ("blued" shoes and/or drums). The service kit consists of replacement front and rear brake linings, rear wheel cylinders and a proportioning valve. These parts must be installed per the appropriate shop manual installation procedure. NOTE: If a misalignment between the drum braking surface and the shoe ledge guides of the brake backing plate is suspected, refer to TSB 82-24 for the appropriate service procedures before installing the service kit (E0UZ-2C178-A). PART NUMBER PART NAME CLASS E0UZ-2C178-A Brake Service Kit C Front/Rear Services OTHER APPLICABLE ARTICLES: 82-24-17 ARTICLE SUPERSEDED: 83-25-18 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP2178A83 TIME: 2.3 Hrs. DLR. CODING: Basic Part No. 2200 Code: 30 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Washer Fluid Level Switch: > 83519 > Mar > 83 > Rear Brakes - Abnormal Rear Brake Wear Brake Shoe: All Technical Service Bulletins Rear Brakes - Abnormal Rear Brake Wear Article No. 83-5-19 BRAKE - REAR - WEAR - AMBULANCE VEHICLES, E & F 250/350 OVER 8500 GVW LIGHT TRUCKS 1976-82 E-350 Ambulance vehicles that experience unusual rear brake wear should be updated to the 1982 ambulance brake package level using the following procedure. (1976 through 1982 vehicles may be affected). Technical Service Bulletin 80-21, Article 80-21-15, dated October 24, 1980 addressed procedures that helped to minimize rear brake wear. This method is still recommended. Under certain circumstances of severe customer usage involving extremely high loads and frequent stopping (i.e., emergency vehicles), the following procedure is also recommended. Perform operation described in Technical Service Bulletin 80-21, Article 80-21-15 and update the front and rear brake systems as follows: ^ Install new front disc brake pad and lining assemblies, D9TZ-2001-A. NOTE: Service or replace disc brake rotor assemblies, if required. ^ 12 x 3 Inch Brakes - Install new rear brake shoe and lining assemblies (Part Number D7TZ-2200-A). Color Code: Secondary 1 green/ 1 red, primary 1 pink/1 yellow right and lefthand. ^ 12 x 2.5 Inch Brakes - Install new rear brake shoe and lining assemblies, (Part Number D7TZ-2200-B). Color Code: Secondary 1 white/1 white primary 1 red/ 1 yellow right and lefthand. ^ Inspect rear brake wheel cylinder; checking cylinder size. Replace 1-1/16 inch diameter R.H. and L.H. wheel cylinder assemblies with 1 inch diameter R.H. and L.H. wheel cylinder assemblies (D6TZ-2261- A/R.H. and D6TZ-2262-A/L.H.). ^ Replace upper brake shoe retracting spring (green) C6TZ-2296-A with C6TZ-2035-A (red). ^ Replace valve with D9TA-2B524-AA. ^ Bleed hydraulic system as outlined in the 1977-1983 Light Truck Shop Manual. ^ Lining Conditioning Procedure Owners should be informed that unnecessary brake wear can be avoided only if the following burnish procedure is performed prior to putting an emergency vehicle into service: ^ 100 moderate snub stops from 40 to 20 mph. ^ 10 stops from 60 to 0 mph at 1/2 mile intervals at maximum deceleration without wheel lock-up. NOTE: These heavy duty shoe and lining service kits must be used in applications specified in the Ford Light Truck Parts Catalog or the Ford Technical Service Bulletin specifying mandatory front linings, rear wheel cylinders and installation procedures for vehicles not originally equipped with these linings. PART NUMBER PART NAME CLASS D9TZ-2001-A Front Shoe & Lining Kit B D7TZ-2200-A Heavy Duty Lining Kit 12" x 3" BM D7TZ-2200-B Heavy Duty Lining Kit 12" x 2.5" B D6TZ-2261-A Wheel Cylinder 1.0" RH A D6TZ-2262-A Wheel Cylinder 1.0" LH A C6TZ-2035-A Retracting Spring Rear Brake A D9TZ-2B257-A Valve C OTHER APPLICABLE ARTICLES: 81-15-19, 80-21-15 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION/TIME: Refer to the Labor Time Standards Manual for applicable operation and time. DLR. CODING: Basic Part No. R2007 Code: 30 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations Wiper Switch: Locations Upper LH Side Of I/P Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 305 Wiper Switch: Testing and Inspection Fig. 4 Wiper Switch Continuity Test Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 306 Fig. 5 Testing wiper switch continuity. 1980 Bronco & F-100---350 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 307 Fig. 5 Wiper Switch Continuity Test 1. Check continuity between switch terminals, Figs. 4 through 6. 2. To detect marginal operation of switch, rotate or slide switch control knob while each reading is being taken. 3. If switch does not show continuity or if poor continuity exists at any switch position, replace switch. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 308 Wiper Switch: Service and Repair E-100---350 1. Disconnect battery ground cable. 2. Remove wiper switch knob. 3. Remove ignition switch bezel from finish panel. 4. Remove light switch knob and shaft assembly by depressing release button on switch housing and pulling straight out. 5. Remove 2 lower attaching screws from finish panel, then pry the 2 upper retainers away from instrument panel. 6. Disconnect wiper switch electrical connector, then remove switch attaching screws and the switch from vehicle. 7. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull Alignment: Customer Interest Steering - Drift/Pull Article No. 85-19-15 STEERING - DRIFT/PULL CASTER SPLIT ADJUSTMENT LIGHT TRUCK 1980-86 F250-350 4x2; 1976-86 E100-350 A side-to-side front wheel caster difference greater than 3/4 degree can contribute to a vehicle drift or pull in the direction of the side with less caster. The service kit (E5TZ-3K064-A) can be used to increase the front wheel caster angle on either or both wheels to balance the caster split to correct a vehicle drift/pull concern. The kit contains complete parts and instructions needed to modify the front radius arm and mount a metal cam on the bottom flange of the radius arm. The kit can increase caster from 1/2 degree to 3 degrees, in 1/2 degree increments. It is not designed to decrease caster. To increase front wheel caster angle of subject vehicles and/or to balance a caster split, the following procedure is suggested: 1. Remove the radius arm from the vehicle as shown in Section 14-21 of the Reference Shop Manual and choose the appropriate paper template applicable to the vehicle model. Figure 8 - POSITIONING TEMPLATE TO LOWER FLANGE OF RADIUS ARM 2. Locate the template (3B474) on the bottom flange of the radius arm. Refer to Figure 8 for a typical arm modification for the right hand radius arm. One template per vehicle model is used to modify both the right and left hand radius arms. When modifying the right hand arm, position the Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 318 template with the printed side downward. The template locates off of one of two existing holes in the radius arm. The E100-350 template is shaped to match the contours of the radius arm. Figure 9 - HOLE DRILLING INSTRUCTIONS - CAM ATTACHMENT TO LOWER FLANGE RADIUS ARM 3. With template secure, make a punch mark at the center of the small hole inside the printed circle. Scribe the slot printed/cut-out on the template and die-grind out the slot at the axle-attaching hole the same size as the slot in the template and de-burr the surface avoiding rounding the edges of the slot. Refer to Figure 9. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 319 Figure 10 - ATTACHMENT OF ADJUSTING CAM TO RADIUS ARM 4. Drill a 0.228 inch diameter hole at the punch mark. Use this hole to mount the adjusting cam with the 1/4-20 self-tapping screw supplied. Refer to Figure 10. 5. Figure 10 shows a typical cam installation. Each hole in the cam represents a 1/2 degree caster increase. A caster increase of approximately 2 degrees for the E100-350, for example, will be obtained by mounting the cam with the selftapping screw in the No. 2 hole of the cam to the lower flange of the radius arm. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 320 Figure 11 - TYPICAL INSTALLATION - FRONT AND RADIUS ARM 6. Figure 11 shows a typical vehicle installation. TORQUE BOLT "A" AND NUT "B" TO 270-330 FT. LBS. When increasing caster 2 degrees or more, the ears of the radius arm should be bent upward slightly to help install and seat the axles. Do not use heat to bend. 7. Reset front wheel toe after installation is complete. AFTER THE DESIRED ALIGNMENT IS ASSURED THE CAM MUST BE WELDED TO THE ARM ARC WELD ONE INCH MINIMUM LENGTH ALONG TWO SIDES OF THE CAM. NOTE: The metal adjusting cam plate has a Ford logo stamped on it to identify it for E100- 150 and F250-350 4x2 vehicles only on vehicles with a front stabilizer bar. The bar mounting bracket may be reworked to provide clearance for the self-tapping screw. Do not use parts from kit E4TZ3K064-A on these vehicles. PART NUMBER PART NAME CLASS E5TZ-3K064-A Kit Caster Adjustment C OTHER APPLICABLE ARTICLES: 85-13-12 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3360B85L TIME: Left - F Series: 2.4 Hrs. Econoline: 2.8 Hrs. OPERATION: SP3360B85R TIME: Right - F Series: 2.4 Hrs. Econoline: 2.8 Hrs. OPERATION: SP3360B85T TIME: Both - F Series: 3.8 Hrs. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 321 Econoline: 4.6 Hrs. OPERATION: 3001A TIME: 0.5 Hr. - Check caster camber and toe-in DLR. CODING: Basic Part No. 3A360 - Code: 36 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 851916 > Sep > 85 > Tires - Front Outside Edge Wear Alignment: Customer Interest Tires - Front Outside Edge Wear Article No. 85-19-16 TIRE WEAR - FRONT - OUTSIDE EDGE LIGHT TRUCK 1976-86 E100-150 Outboard shoulder wear, predominantly in lightly loaded city-delivery type use, is aggravated by excessive positive wheel camber in turning. The caster adjustment kit described in TSB 85-19-15 can be used to increase caster of either wheel up to 3 degrees in 1/2 degree increments. The kit contains complete instructions for modifying the front radius arms and mounting a metal adjusting cam to the bottom flange of each radius arm. Cams must be arc-welded a minimum of one inch along two sides of the cam to the lower flange of the radius arm. Increasing caster the full 3 degrees effectively reduces camber of the outboard wheel in a turn 1.5 degrees. Increasing caster more than 3 degrees is not recommended since this may cause complaints of wheel shimmy and/or excessive steering efforts. Also, caster should not be increased on vehicles built since April 1, 1984. These vehicles have the 3 degree caster increase already built into the axles which have axle part numbers E4UA-6-BA and E4UA-7-BA embossed on the face of each axle. Three other significant factors may also contribute to outboard shoulder wear. They are excessive toe-in (generally greater than 5/32 inch), excessive cornering speeds, and low tire pressure. After any adjustments to front end alignment, toe should be adjusted to zero. On vehicles subject to extensive city-delivery use, toe may be set up to 1/16 inch toe-out for optimum tire life. PART NUMBER PART NAME CLASS E5TZ-3K064-A Kit Caster Adjustment C OTHER APPLICABLE ARTICLES: 85-19-15 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3360B85T TIME: 4.6 Hrs. OPERATION: 3001A TIME: 0.5 Hr. - Check caster camber and toe-in DLR. CODING: Basic Part No. 3A360 - Code: 36 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull Alignment: All Technical Service Bulletins Steering - Drift/Pull Article No. 85-19-15 STEERING - DRIFT/PULL CASTER SPLIT ADJUSTMENT LIGHT TRUCK 1980-86 F250-350 4x2; 1976-86 E100-350 A side-to-side front wheel caster difference greater than 3/4 degree can contribute to a vehicle drift or pull in the direction of the side with less caster. The service kit (E5TZ-3K064-A) can be used to increase the front wheel caster angle on either or both wheels to balance the caster split to correct a vehicle drift/pull concern. The kit contains complete parts and instructions needed to modify the front radius arm and mount a metal cam on the bottom flange of the radius arm. The kit can increase caster from 1/2 degree to 3 degrees, in 1/2 degree increments. It is not designed to decrease caster. To increase front wheel caster angle of subject vehicles and/or to balance a caster split, the following procedure is suggested: 1. Remove the radius arm from the vehicle as shown in Section 14-21 of the Reference Shop Manual and choose the appropriate paper template applicable to the vehicle model. Figure 8 - POSITIONING TEMPLATE TO LOWER FLANGE OF RADIUS ARM 2. Locate the template (3B474) on the bottom flange of the radius arm. Refer to Figure 8 for a typical arm modification for the right hand radius arm. One template per vehicle model is used to modify both the right and left hand radius arms. When modifying the right hand arm, position the Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 331 template with the printed side downward. The template locates off of one of two existing holes in the radius arm. The E100-350 template is shaped to match the contours of the radius arm. Figure 9 - HOLE DRILLING INSTRUCTIONS - CAM ATTACHMENT TO LOWER FLANGE RADIUS ARM 3. With template secure, make a punch mark at the center of the small hole inside the printed circle. Scribe the slot printed/cut-out on the template and die-grind out the slot at the axle-attaching hole the same size as the slot in the template and de-burr the surface avoiding rounding the edges of the slot. Refer to Figure 9. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 332 Figure 10 - ATTACHMENT OF ADJUSTING CAM TO RADIUS ARM 4. Drill a 0.228 inch diameter hole at the punch mark. Use this hole to mount the adjusting cam with the 1/4-20 self-tapping screw supplied. Refer to Figure 10. 5. Figure 10 shows a typical cam installation. Each hole in the cam represents a 1/2 degree caster increase. A caster increase of approximately 2 degrees for the E100-350, for example, will be obtained by mounting the cam with the selftapping screw in the No. 2 hole of the cam to the lower flange of the radius arm. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 333 Figure 11 - TYPICAL INSTALLATION - FRONT AND RADIUS ARM 6. Figure 11 shows a typical vehicle installation. TORQUE BOLT "A" AND NUT "B" TO 270-330 FT. LBS. When increasing caster 2 degrees or more, the ears of the radius arm should be bent upward slightly to help install and seat the axles. Do not use heat to bend. 7. Reset front wheel toe after installation is complete. AFTER THE DESIRED ALIGNMENT IS ASSURED THE CAM MUST BE WELDED TO THE ARM ARC WELD ONE INCH MINIMUM LENGTH ALONG TWO SIDES OF THE CAM. NOTE: The metal adjusting cam plate has a Ford logo stamped on it to identify it for E100- 150 and F250-350 4x2 vehicles only on vehicles with a front stabilizer bar. The bar mounting bracket may be reworked to provide clearance for the self-tapping screw. Do not use parts from kit E4TZ3K064-A on these vehicles. PART NUMBER PART NAME CLASS E5TZ-3K064-A Kit Caster Adjustment C OTHER APPLICABLE ARTICLES: 85-13-12 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3360B85L TIME: Left - F Series: 2.4 Hrs. Econoline: 2.8 Hrs. OPERATION: SP3360B85R TIME: Right - F Series: 2.4 Hrs. Econoline: 2.8 Hrs. OPERATION: SP3360B85T TIME: Both - F Series: 3.8 Hrs. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 334 Econoline: 4.6 Hrs. OPERATION: 3001A TIME: 0.5 Hr. - Check caster camber and toe-in DLR. CODING: Basic Part No. 3A360 - Code: 36 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 851916 > Sep > 85 > Tires - Front Outside Edge Wear Alignment: All Technical Service Bulletins Tires - Front Outside Edge Wear Article No. 85-19-16 TIRE WEAR - FRONT - OUTSIDE EDGE LIGHT TRUCK 1976-86 E100-150 Outboard shoulder wear, predominantly in lightly loaded city-delivery type use, is aggravated by excessive positive wheel camber in turning. The caster adjustment kit described in TSB 85-19-15 can be used to increase caster of either wheel up to 3 degrees in 1/2 degree increments. The kit contains complete instructions for modifying the front radius arms and mounting a metal adjusting cam to the bottom flange of each radius arm. Cams must be arc-welded a minimum of one inch along two sides of the cam to the lower flange of the radius arm. Increasing caster the full 3 degrees effectively reduces camber of the outboard wheel in a turn 1.5 degrees. Increasing caster more than 3 degrees is not recommended since this may cause complaints of wheel shimmy and/or excessive steering efforts. Also, caster should not be increased on vehicles built since April 1, 1984. These vehicles have the 3 degree caster increase already built into the axles which have axle part numbers E4UA-6-BA and E4UA-7-BA embossed on the face of each axle. Three other significant factors may also contribute to outboard shoulder wear. They are excessive toe-in (generally greater than 5/32 inch), excessive cornering speeds, and low tire pressure. After any adjustments to front end alignment, toe should be adjusted to zero. On vehicles subject to extensive city-delivery use, toe may be set up to 1/16 inch toe-out for optimum tire life. PART NUMBER PART NAME CLASS E5TZ-3K064-A Kit Caster Adjustment C OTHER APPLICABLE ARTICLES: 85-19-15 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3360B85T TIME: 4.6 Hrs. OPERATION: 3001A TIME: 0.5 Hr. - Check caster camber and toe-in DLR. CODING: Basic Part No. 3A360 - Code: 36 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 339 Alignment: By Symptom Technical Service Bulletin # 851916 Date: 850901 Tires - Front Outside Edge Wear Article No. 85-19-16 TIRE WEAR - FRONT - OUTSIDE EDGE LIGHT TRUCK 1976-86 E100-150 Outboard shoulder wear, predominantly in lightly loaded city-delivery type use, is aggravated by excessive positive wheel camber in turning. The caster adjustment kit described in TSB 85-19-15 can be used to increase caster of either wheel up to 3 degrees in 1/2 degree increments. The kit contains complete instructions for modifying the front radius arms and mounting a metal adjusting cam to the bottom flange of each radius arm. Cams must be arc-welded a minimum of one inch along two sides of the cam to the lower flange of the radius arm. Increasing caster the full 3 degrees effectively reduces camber of the outboard wheel in a turn 1.5 degrees. Increasing caster more than 3 degrees is not recommended since this may cause complaints of wheel shimmy and/or excessive steering efforts. Also, caster should not be increased on vehicles built since April 1, 1984. These vehicles have the 3 degree caster increase already built into the axles which have axle part numbers E4UA-6-BA and E4UA-7-BA embossed on the face of each axle. Three other significant factors may also contribute to outboard shoulder wear. They are excessive toe-in (generally greater than 5/32 inch), excessive cornering speeds, and low tire pressure. After any adjustments to front end alignment, toe should be adjusted to zero. On vehicles subject to extensive city-delivery use, toe may be set up to 1/16 inch toe-out for optimum tire life. PART NUMBER PART NAME CLASS E5TZ-3K064-A Kit Caster Adjustment C OTHER APPLICABLE ARTICLES: 85-19-15 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3360B85T TIME: 4.6 Hrs. OPERATION: 3001A TIME: 0.5 Hr. - Check caster camber and toe-in DLR. CODING: Basic Part No. 3A360 - Code: 36 Technical Service Bulletin # 851915 Date: 850926 Steering - Drift/Pull Article No. 85-19-15 STEERING - DRIFT/PULL CASTER SPLIT ADJUSTMENT LIGHT TRUCK 1980-86 F250-350 4x2; 1976-86 E100-350 A side-to-side front wheel caster difference greater than 3/4 degree can contribute to a vehicle drift or pull in the direction of the side with less caster. The service kit (E5TZ-3K064-A) can be used to increase the front wheel caster angle on either or both wheels to balance the caster split to correct a vehicle drift/pull concern. The kit contains complete parts and instructions needed to modify the front radius arm and mount a metal cam on the bottom flange of the radius arm. The kit can increase caster from 1/2 degree to 3 degrees, in 1/2 degree increments. It is not designed to decrease caster. To increase front wheel caster angle of subject vehicles and/or to balance a caster split, the following procedure is suggested: 1. Remove the radius arm from the vehicle as shown in Section 14-21 of the Reference Shop Manual and choose the appropriate paper template applicable to the vehicle model. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 340 Figure 8 - POSITIONING TEMPLATE TO LOWER FLANGE OF RADIUS ARM 2. Locate the template (3B474) on the bottom flange of the radius arm. Refer to Figure 8 for a typical arm modification for the right hand radius arm. One template per vehicle model is used to modify both the right and left hand radius arms. When modifying the right hand arm, position the template with the printed side downward. The template locates off of one of two existing holes in the radius arm. The E100-350 template is shaped to match the contours of the radius arm. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 341 Figure 9 - HOLE DRILLING INSTRUCTIONS - CAM ATTACHMENT TO LOWER FLANGE RADIUS ARM 3. With template secure, make a punch mark at the center of the small hole inside the printed circle. Scribe the slot printed/cut-out on the template and die-grind out the slot at the axle-attaching hole the same size as the slot in the template and de-burr the surface avoiding rounding the edges of the slot. Refer to Figure 9. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 342 Figure 10 - ATTACHMENT OF ADJUSTING CAM TO RADIUS ARM 4. Drill a 0.228 inch diameter hole at the punch mark. Use this hole to mount the adjusting cam with the 1/4-20 self-tapping screw supplied. Refer to Figure 10. 5. Figure 10 shows a typical cam installation. Each hole in the cam represents a 1/2 degree caster increase. A caster increase of approximately 2 degrees for the E100-350, for example, will be obtained by mounting the cam with the selftapping screw in the No. 2 hole of the cam to the lower flange of the radius arm. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 343 Figure 11 - TYPICAL INSTALLATION - FRONT AND RADIUS ARM 6. Figure 11 shows a typical vehicle installation. TORQUE BOLT "A" AND NUT "B" TO 270-330 FT. LBS. When increasing caster 2 degrees or more, the ears of the radius arm should be bent upward slightly to help install and seat the axles. Do not use heat to bend. 7. Reset front wheel toe after installation is complete. AFTER THE DESIRED ALIGNMENT IS ASSURED THE CAM MUST BE WELDED TO THE ARM ARC WELD ONE INCH MINIMUM LENGTH ALONG TWO SIDES OF THE CAM. NOTE: The metal adjusting cam plate has a Ford logo stamped on it to identify it for E100- 150 and F250-350 4x2 vehicles only on vehicles with a front stabilizer bar. The bar mounting bracket may be reworked to provide clearance for the self-tapping screw. Do not use parts from kit E4TZ3K064-A on these vehicles. PART NUMBER PART NAME CLASS E5TZ-3K064-A Kit Caster Adjustment C OTHER APPLICABLE ARTICLES: 85-13-12 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3360B85L TIME: Left - F Series: 2.4 Hrs. Econoline: 2.8 Hrs. OPERATION: SP3360B85R TIME: Right - F Series: 2.4 Hrs. Econoline: 2.8 Hrs. OPERATION: SP3360B85T TIME: Both - F Series: 3.8 Hrs. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 344 Econoline: 4.6 Hrs. OPERATION: 3001A TIME: 0.5 Hr. - Check caster camber and toe-in DLR. CODING: Basic Part No. 3A360 - Code: 36 Technical Service Bulletin # 851916 Date: 850901 Tires - Front Outside Edge Wear Article No. 85-19-16 TIRE WEAR - FRONT - OUTSIDE EDGE LIGHT TRUCK 1976-86 E100-150 Outboard shoulder wear, predominantly in lightly loaded city-delivery type use, is aggravated by excessive positive wheel camber in turning. The caster adjustment kit described in TSB 85-19-15 can be used to increase caster of either wheel up to 3 degrees in 1/2 degree increments. The kit contains complete instructions for modifying the front radius arms and mounting a metal adjusting cam to the bottom flange of each radius arm. Cams must be arc-welded a minimum of one inch along two sides of the cam to the lower flange of the radius arm. Increasing caster the full 3 degrees effectively reduces camber of the outboard wheel in a turn 1.5 degrees. Increasing caster more than 3 degrees is not recommended since this may cause complaints of wheel shimmy and/or excessive steering efforts. Also, caster should not be increased on vehicles built since April 1, 1984. These vehicles have the 3 degree caster increase already built into the axles which have axle part numbers E4UA-6-BA and E4UA-7-BA embossed on the face of each axle. Three other significant factors may also contribute to outboard shoulder wear. They are excessive toe-in (generally greater than 5/32 inch), excessive cornering speeds, and low tire pressure. After any adjustments to front end alignment, toe should be adjusted to zero. On vehicles subject to extensive city-delivery use, toe may be set up to 1/16 inch toe-out for optimum tire life. PART NUMBER PART NAME CLASS E5TZ-3K064-A Kit Caster Adjustment C OTHER APPLICABLE ARTICLES: 85-19-15 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3360B85T TIME: 4.6 Hrs. OPERATION: 3001A TIME: 0.5 Hr. - Check caster camber and toe-in DLR. CODING: Basic Part No. 3A360 - Code: 36 Technical Service Bulletin # 851915 Date: 850926 Steering - Drift/Pull Article No. 85-19-15 STEERING - DRIFT/PULL CASTER SPLIT ADJUSTMENT LIGHT TRUCK 1980-86 F250-350 4x2; 1976-86 E100-350 A side-to-side front wheel caster difference greater than 3/4 degree can contribute to a vehicle drift or pull in the direction of the side with less caster. The service kit (E5TZ-3K064-A) can be used to increase the front wheel caster angle on either or both wheels to balance the caster split to correct a vehicle drift/pull concern. The kit contains complete parts and instructions needed to modify the front radius arm and mount a metal cam on the bottom flange of the radius arm. The kit can increase caster from 1/2 degree to 3 degrees, in 1/2 degree increments. It is not designed to decrease caster. To increase front wheel caster angle of subject vehicles and/or to balance a caster split, the following procedure is suggested: 1. Remove the radius arm from the vehicle as shown in Section 14-21 of the Reference Shop Manual and choose the appropriate paper template applicable to the vehicle model. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 345 Figure 8 - POSITIONING TEMPLATE TO LOWER FLANGE OF RADIUS ARM 2. Locate the template (3B474) on the bottom flange of the radius arm. Refer to Figure 8 for a typical arm modification for the right hand radius arm. One template per vehicle model is used to modify both the right and left hand radius arms. When modifying the right hand arm, position the template with the printed side downward. The template locates off of one of two existing holes in the radius arm. The E100-350 template is shaped to match the contours of the radius arm. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 346 Figure 9 - HOLE DRILLING INSTRUCTIONS - CAM ATTACHMENT TO LOWER FLANGE RADIUS ARM 3. With template secure, make a punch mark at the center of the small hole inside the printed circle. Scribe the slot printed/cut-out on the template and die-grind out the slot at the axle-attaching hole the same size as the slot in the template and de-burr the surface avoiding rounding the edges of the slot. Refer to Figure 9. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 347 Figure 10 - ATTACHMENT OF ADJUSTING CAM TO RADIUS ARM 4. Drill a 0.228 inch diameter hole at the punch mark. Use this hole to mount the adjusting cam with the 1/4-20 self-tapping screw supplied. Refer to Figure 10. 5. Figure 10 shows a typical cam installation. Each hole in the cam represents a 1/2 degree caster increase. A caster increase of approximately 2 degrees for the E100-350, for example, will be obtained by mounting the cam with the selftapping screw in the No. 2 hole of the cam to the lower flange of the radius arm. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 348 Figure 11 - TYPICAL INSTALLATION - FRONT AND RADIUS ARM 6. Figure 11 shows a typical vehicle installation. TORQUE BOLT "A" AND NUT "B" TO 270-330 FT. LBS. When increasing caster 2 degrees or more, the ears of the radius arm should be bent upward slightly to help install and seat the axles. Do not use heat to bend. 7. Reset front wheel toe after installation is complete. AFTER THE DESIRED ALIGNMENT IS ASSURED THE CAM MUST BE WELDED TO THE ARM ARC WELD ONE INCH MINIMUM LENGTH ALONG TWO SIDES OF THE CAM. NOTE: The metal adjusting cam plate has a Ford logo stamped on it to identify it for E100- 150 and F250-350 4x2 vehicles only on vehicles with a front stabilizer bar. The bar mounting bracket may be reworked to provide clearance for the self-tapping screw. Do not use parts from kit E4TZ3K064-A on these vehicles. PART NUMBER PART NAME CLASS E5TZ-3K064-A Kit Caster Adjustment C OTHER APPLICABLE ARTICLES: 85-13-12 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3360B85L TIME: Left - F Series: 2.4 Hrs. Econoline: 2.8 Hrs. OPERATION: SP3360B85R TIME: Right - F Series: 2.4 Hrs. Econoline: 2.8 Hrs. OPERATION: SP3360B85T TIME: Both - F Series: 3.8 Hrs. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 349 Econoline: 4.6 Hrs. OPERATION: 3001A TIME: 0.5 Hr. - Check caster camber and toe-in DLR. CODING: Basic Part No. 3A360 - Code: 36 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 350 Alignment: Specifications Camber Caster Toe Ride Height 3.25-3.50 in -1 3/4 to -1/4 deg +6 1/4 to +8 deg 1/8 in 3.50-3.75 in -1 1/2 to + 1/4 deg +5 3/4 to +7 1/4 deg 1/8 in 4.00-4.25 in -1/2 to + 1 1/4 deg +4 1/2 to +5 3/4 deg 1/8 in 4.25-4.50 in 0 to + 1 3/4 deg +4 to +5 1/4 deg 1/8 in 4.50-4.75 in + 1/2 to +2 1/4 deg +3 1/4 to +4 1/2 deg 1/8 in 5.00-5.25 in +1 1/2 to + 3 1/4 deg +2 to +3 1/4 deg 1/8 in 5.25-5.50 in +2 to +3 3/4 deg +1 1/2 to +2 3/4 deg 1/8 in Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 351 Alignment: Service and Repair Fig. 1 Measuring Ride Height Fig. 7 Measuring riding height. 1980---85 F-100---350 & Bronco Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 352 Fig. 8 Measuring Riding Height Prior to checking caster and camber, ensure vehicle front ride height is within {1/8} inch side to side 1980-87 E-100-350. On 1980-87 F-100-350 models, the left side ride height should be within 0-{3/8} inch higher than the right side ride height. On 1980-87 F-150-350 (4x4) and Bronco, the front ride heights should be within {3/16} inch side to side. Refer to Figs. 6, 7 and 8. If the vehicle ride heights are not within specifications, redistribute load on loaded vehicles or slightly load empty vehicles on one side. If the ride heights cannot be brought within specifications, verify correct spring installation. The ride height variations stated, are for checking purposes only. The vehicle does not have to operate within these specifications. Check and correct as necessary all tire inflation pressures, then check front tires for the same size, ply rating and load range. Check front wheel bearings and adjust as necessary. If all the above checks have been made, check wheel alignment with suitable alignment equipment. Using the ride heights obtained earlier, compare caster and camber readings to those listed in the ``Wheel Alignment Specifications Chart''. If the caster and camber angles exceed the specifications, inspect front end for damaged suspension components. Replace as necessary. Alignment equipment indicates a true reading only when the vehicle's frame is horizontal. Therefore, if the frame is not level (due to tire, spring or load differences), the caster angle reading must be modified to compensate for the frame angles. If the front is higher than the rear, subtract the amount of angle from the reading. If the front is lower than the rear, add the angle. To check frame angle, use a spirit protractor, and take the frame angle measurement on the lower frame flange at the flat area immediately adjacent to the rear spring front hanger. 1980-85 4 X 2 MODELS EXC. 1982-85 F-100-350 W/BALL JOINTS The camber and caster angles are designed into the front end and are not adjustable. TOE-IN, ADJUST Check the steering wheel spoke position when the front wheels are in the straight ahead position. If the spokes are not in the normal position, they can be adjusted while toe-in is being adjusted. 1. Loosen clamp bolts on each tie rod end sleeve. 2. Adjust toe-in. If steering wheel spokes are in their normal position, lengthen or shorten both rods equally to obtain correct toe-in. If spokes are not in normal position, make necessary rod adjustments to obtain correct toe-in and steering wheel spoke alignment. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications SPECIFICATIONS Pressure .............................................................................................................................................. .............................................................. 6.0-8.0 PSI Volume .............................................................. ................................................................................................................................. 1 pint in 20 seconds NOTE: Measurements taken with engine idling. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 357 Fuel Pressure: Testing and Inspection PRESSURE TEST 1. Connect a suitable pressure gauge (0-15 PSI) to the carburetor end of the fuel line. WARNING: Use care to prevent combustion of spilled fuel. 2. Start the engine (it should be able to run for over 30 seconds on the fuel in the carburetor bowl) and read the pressure after 10 seconds. If pump pressure is too low or too high install a new fuel pump. Fuel Pump Pressure ............................................................................................................................ ................................................. 6.0-8.0 PSI 3. Reconnect fuel line at filter and install air cleaner. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications IDLE SPEED SPECIFICATIONS Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Curb Idle Speed Idle Speed: Adjustments Curb Idle Speed Identification CARBURETOR IDENTIFICATION 2150-2V, 2150A-2V Carburetor Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Curb Idle Speed > Page 363 Variable Venturi, 7200-VV Carburetor Type 2150-2V CURB IDLE SPEED ADJUSTMENT - Place the transmission in Neutral (manual) or Park (automatic). - Bring engine to normal operating temperature (upper radiator hose hot). - Place the transmission in the specified gear. See: Specifications Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Curb Idle Speed > Page 364 - Check curb idle rpm. Adjust to specification. See: Specifications - Place the transmission in Neutral (manual) or Park (automatic). Rev the engine momentarily. Place the transmission in specified position, and recheck curb idle rpm. Readjust if required. Type 7200-VV Carburetor CURB IDLE SPEED ADJUSTMENT - Place the transmission in Neutral (manual) or Park (automatic). - Bring the engine to normal operating temperature. - Disconnect purge hose on canister side of evaporator purge solenoid. Check to ensure that purge vacuum is present (solenoid has opened, will require a 3-5 minute wait after starting engine, followed by a short time at part throttle. Reconnect purge hose. - Disconnect and plug the vacuum hose to the Vacuum Operated Throttle Modulator (VOTM) kicker. - Place the transmission in specified position. See: Specifications With Automatic Transmission Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Curb Idle Speed > Page 365 With Manual Transmission - Check/adjust curb idle rpm. See: Specifications - Place the transmission in Neutral or Park. Rev the engine momentarily. Place the transmission in specified position and recheck curb idle rpm. Readjust if required. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Curb Idle Speed > Page 366 Idle Speed: Adjustments Fast Idle Speed Identification CARBURETOR IDENTIFICATION 2150-2V, 2150A-2V Carburetor Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Curb Idle Speed > Page 367 Variable Venturi, 7200-VV Carburetor Type 2150-2V Carburetor FAST IDLE SPEED ADJUSTMENT - Place the transmission in Park (automatic) or Neutral (manual). - Bring the engine to normal operating temperature. - Disconnect the vacuum hose at the EGR valve and plug. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Curb Idle Speed > Page 368 - Place the fast idle adjustment mechanism on top step of fast idle cam. Check/adjust fast idle rpm to specification. See: Specifications - Recheck for repeatability. - Remove the plug from the EGR vacuum hose and reconnect. Type 7200-VV Carburetor FAST IDLE SPEED ADJUSTMENT - Place the transmission in Neutral (manual) or Park (automatic). - Bring the engine to normal operating temperature. - Disconnect purge hose on canister side of evaporator purge solenoid. Check to ensure that purge vacuum is present (solenoid has opened, will require a 3-5 minute wait after starting engine, followed by a short time at part throttle. Reconnect purge hose. Disconnect the vacuum hose at the EGR valve and plug. - Place the fast idle adjustment mechanism on the second step of the fast idle cam. - Check/adjust fast idle rpm to specification. Recheck for repeatability. See: Specifications - Remove the plug from the EGR vacuum hose and reconnect. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Technical Service Bulletins > Air Cleaner - Sealing Procedure Air Cleaner Housing: Technical Service Bulletins Air Cleaner - Sealing Procedure Article No. 83-25-21-S AIR CLEANER SEALING - 4.9L (1982-83 F-SERIES AND BRONCO ONLY) AND ALL UNITS WITH 5.0L, 5.8L OR 7.5L ENGINES. UNITS OPERATED IN DUSTY AND/OR OFF-ROAD CONDITIONS ARTICLE ALSO INCLUDES SEALING OF 7200VV CARBURETOR ON UNITS SO EQUIPPED LIGHT TRUCKS 1980-83 E, F AND BRONCO This is a re-write of TSB 83-25-21 (December 12, 1983). The air cleaner part numbers listed in the TSB are of insufficient detail and are therefore being deleted from the TSB. Due to the variety of different air cleaners used, part numbers have not been included in this TSB. See your normal parts listing for these part numbers. The subject vehicles operated in dusty/off-road conditions may experience an air cleaner sealing concern which could lead to engine oil consumption or, on 7200 VV carburetor equipped vehicles, a poor running condition. The following procedure should minimize these concerns. 1. Remove the air cleaner assembly from the engine and remove any loose debris from inside the tray. Replace the air cleaner assembly (9600) on all 1983 4.9L, 5.0L, 5.8L and, 7.5L equipped light trucks except the 1983 Econoline with the 4.9L engine. Due to the variety of different air cleaners used, part numbers have not been included in this TSB. See your normal parts listings for these part numbers. 2. Wipe the sealing surfaces clean on the tray and cover and inspect for any dents or damage that would prevent a good seal. Replace any damaged components. 3. Inspect the air cleaner to carburetor gasket for proper installation. If the gasket appears crimped or damaged, replace it with a new sticky-back gasket. Prior to replacing the gasket, clean the carburetor flange. Install the new gasket sticky side down and press all the gasket down to assure a tight bond. Gasket parts numbers: 4.9L - C8DZ-9654-A, 5.0L/5.8L/7.5L - D8ZZ-9654-A. FIGURE 24 4. For F-Series and Bronco only, relocate the zip tube inlet. a) Detach the zip tube inlet from the radiator support. b) Move the inlet to the top rear of the wheel wellhousing per Figure 24. c) Secure the zip tube to the top of the housing with a nylon tie-down strap. NOTE: At high temperatures, an octane ping may occur. If it persists, the zip tube must be reinstalled to the radiator support. 5. Replace the PCV filter. For 4.9L, 5.0L-2V, 5.8L-2V and 7.5L-4V engines replace the PCV filter in the air cleaner with an in-line filter. a. Remove and discard the crankcase breather cap to PCV filter hose (closure hose), PCV filter in the air cleaner, the adapter at the air cleaner and the adapter retaining clip. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Technical Service Bulletins > Air Cleaner - Sealing Procedure > Page 373 b. Drill a 5/16" hole in the side wall of the air cleaner approximately 12" to the rear of the existing crankcase closure hole for 5.0L and 5.8L and approximately 6" to the rear on 7.5L. (The 4.9L does not need a new hole). c. Install a 1/2" hose (E2AZ-6853-A) to the existing adaptor in the valve cover oil fill cap (2 pcs. 2-5/8" long for 4.9L, 18" long for 5.0L/5.8L, 12" long for 7.5L). d. At a convenient location, cut the hose and install an in-line filter E2AZ-6A768-A for 5.0L, 5.8L and 7.5L. On the 4.9L, install the filter between the 2-5/8" long pieces installed in (c.). NOTE: Install the filter with the wire mesh toward the oil fill cap. The mesh can be seen by looking into the end of the filter assembly. e. Install an adapter E43Z-9E606-A in the air cleaner and attach using a retaining clip 383741-S. Center the adapter elbow in the new hole for 5.0L, 5.8L and 7.5L. Use the existing PCV filter (closure) pack hole for 4.9L. f. Cut the PCV filter (closure) hose to proper length and attach to the adapter. g. Plug the old hole in the tray with plug 377678-S for 5.0L, 5.8L and 7.5L only. FIGURE 25 6. For 5.0L and 5.8L engines with a 7200 VV carburetor, clean and seal the carburetor to prevent dirt migration through the choke rod and accelerator pump rod holes (Refer to Figure 25). a. Remove the carburetor from the vehicle. b. Without disassembling the carburetor, thoroughly clean with Ford Automatic Choke Cleaner or equivalent, all of the choke linkage and accelerator pump linkage on the top and sides of the carburetor. Pay particular attention to the top and bottom of the upper body casting around the choke and accelerator pump rods. Allow cleaner to evaporate or blow dry with shop air. c. Remove stepper motor, gasket, pintle and spring. Clean pintle and pintle cavity in main body casting thoroughly with Ford Automatic Choke Cleaner or equivalent. Do not re-install stepper motor at this time. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Technical Service Bulletins > Air Cleaner - Sealing Procedure > Page 374 FIGURE 24 d. Hold throttle lever in the wide-open throttle position to raise the accelerator pump rod. With a toothpick, or other sharp tool, apply any commercially available silicone RTV (such as Dow Corning "Silastic") to the top side of the upper body casting around the accelerator pump rod (Figure 24). Fill the hole completely around the rods from the top side only and release the throttle lever. e. With a rubber band, tie the throttle lever in closed-throttle position. Push fast idle cam to "off" position so that choke rod is fully raised. Fast idle cam should remain in "off" position. f. With a toothpick, apply silicone RTV to bottom side of upper body casting around the choke shaft rod. Fill the hole completely around the rod from the bottom side only. g. Install the spring, pintle, gasket, and stepper motor. h. Allow carburetor to stand at room temperature for 24 hours without disturbing silicone RTV. i. After 24-hour cure, remove rubber band from throttle lever, and open throttle to break (free) accelerator pump rod from silicone RTV. Bulk of RTV sealant should remain attached to upper body. j. Manually exercise choke linkage to break (free) choke rod from silicone RTV. Bulk of RTV sealant should remain attached to upper body. k. Re-install carburetor on vehicle. 7. Re-install and secure the air cleaner assembly as follows: a. Set the air cleaner tray assembly on the carburetor and check that nothing is preventing the tray seating securely and completely sealing the flange. b. Connect and secure the vacuum hoses. c. Install and seat a new heavy duty air cleaner element in the tray. Use E2TZ-9601-B (FA-732) for 4.9L and E0TZ-9601-A (FA-688) for 5.0L/5.8L. Use non-heavy duty element for 7.5L. NOTE: Use of incorrect element will allow dirt to be ingested and will damage the engine. d. Install the air cleaner cover and place the washer grommet rubber side down. Torque the wing nut hand tight (20 in.lbs.). Try to rotate the air cleaner assembly slightly. If it resists rotation, sealing to the carburetor is assured. e. Connect the crankcase filter hose securely. f. Install the heat riser tube. Connect the fresh air zip tube. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Technical Service Bulletins > Air Cleaner - Sealing Procedure > Page 375 Obtain an Authorized Modifications decal and list the date, dealer number and summary of alterations performed. Select a prominent place adjacent to the Vehicle Emission Control Information decal suitable for installing the Authorized Modifications decal. Clean the area, install the decal and cover it with a clear plastic decal shield. PART NUMBER PART NAME CLASS E2AZ-6A768-A PCV Filter C E2AZ-6853-A 1/2" PCV Hose C E43Z-9E606-A Adapter C E2TZ-9601-B Air Filter Element AM E0TZ-9601-A Air Filter Element AM C6TZ-9697-A Washer AM D8ZZ-9654-A Gasket A 377678-S Plug BR E3AZ-19562-A RTV Sealer A 390013-S36B Wing Nut S C8DZ-9654-A Gasket AM OTHER APPLICABLE ARTICLES: 83-25-21 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP9600C84 TIME: 6 cyl. - 0.5 Hr. 8 cyl. - 1.1 Hrs. DLR. CODING: Basic Part No. 9600 Code: 49 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel Filter - Replacement Information Fuel Filter: Technical Service Bulletins Fuel Filter - Replacement Information Article No. 85-6-10 FUEL FILTER REPLACEMENT INFORMATION - ALL WITH FUEL FILTERS ATTACHED TO THE CARBURETOR AND/OR FUEL LINE WITH A RUBBER HOSE FORD ALL 1985 AND PRIOR LINCOLN-MERCURY ALL 1985 AND PRIOR LIGHT TRUCK ALL 1985 AND PRIOR New fuel connector hoses and clamps should be used whenever a fuel filter is replaced. Due to possible deterioration of hose materials which may result if a vehicle is fueled with gasoline containing excessive levels of methanol or ethanol, a new fuel hose and clamps should be installed when the fuel filter is changed. DO NOT REUSE OLD HOSES OR CLAMPS. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Screw In Type Fuel Filter: Service and Repair Screw In Type REMOVAL 1. Remove the air cleaner assembly. 2. Loosen and remove the fuel tube from the filter. 3. Unscrew the filter from the carburetor. INSTALLATION 1. Apply one drop of thread sealer to the external thread of a new filter. Thread the filter into the carburetor inlet port. 2. Tighten the filter to 9.0-11.0 Nm (80-100 in-lbs). 3. Apply ESE-M2C39-E or equivalent oil to the fuel supply tube nut and flare , and hand start the nut into the fuel filter inlet approximately two threads. 4. Use an 11/16 inch wrench on the fuel filter to prevent the filter from rotating. Tighten the fuel filter to supply tube nut to 20-24 Nm (15-18 ft-lb). 5. Install air cleaner assembly. 6. Start the engine and check for fuel leaks. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Screw In Type > Page 382 Fuel Filter: Service and Repair Inlet Fitting Type REMOVAL - Remove the air cleaner. - Hold the fuel filter inlet hex nut with a backup wrench and unscrew the fuel line tube nut from the fuel filter inlet. WARNING: Use care to prevent combustion from fuel spillage. - Unscrew the fuel inlet fitting. Remove the gasket, filter and spring. - Discard the gasket and filter. INSTALLATION - Install the spring, new filter and gasket. - Hand start the fuel inlet fitting into the carburetor then, tighten to 10-24 Nm (90-125 lb-in). - Apply oil, ESE-M2C39-E or equivalent to the fuel tube nut threads and tube flare. - Hand start the fuel line tube nut into the fuel inlet fitting (approximately two threads). - Use a backup wrench on the fuel inlet fitting while tightening the fuel line tube nut to 20-24 Nm (15-18 lb-ft). - Start the engine and check for fuel leak. - Install the air cleaner. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > With EEC III Firing Order: Specifications With EEC III With EEC III The cylinders are numbered 1-4 on the Right side, starting with the front, and 5-8 on the left side, ending with the rear. Because of the unique dual level rotor used by the EEC-III Ignition system, the engine's firing order cannot be read off the top of Firing Order 1-3-7-2-6-5-4-8 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > With EEC III > Page 387 Firing Order: Specifications Without EEC III Without EEC III Firing Order 1-3-7-2-6-5-4-8 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Description and Operation Ignition Timing Connector: Description and Operation Fig. 20 Ignition Timing Vacuum Switch Below vacuum setting, this switch, Fig. 20, used on some vehicles, is open and signals the ignition module to retard spark timing. The switch is closed above the vacuum setting and the ignition module is in the non-retard spark timing mode. Calibration resistors inside the switch control the amount of retard. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Description and Operation > Page 392 Ignition Timing Connector: Testing and Inspection Ignition Timing Vacuum Switch Ignition Timing Vacuum Switch Test Chart 1. Disconnect switch from ignition module. 2. Connect suitable ohmmeter across switch terminals and compare resistance measured to ``less than'' values in the Ignition Timing vacuum Switch Test chart. 3. Apply vacuum to switch, using an outside vacuum source. Compare resistance now measured across switch terminals to ``greater than'' values in the Ignition Timing vacuum Switch Test chart. 4. Replace switch if resistance is not within specifications. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations > With Electronic Engine Controls (EEC) Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations > With Electronic Engine Controls (EEC) > Page 397 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Diagrams Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams Ignition Cable: Diagrams Spark Plug Wire Routing Ford F 250 5.8L Firing Order Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Page 404 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Page 405 Ignition Cable: Testing and Inspection Spark Plug Wire Resistance *** UPDATED BY TSB #85-9-33 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Advance Unit > Component Information > Specifications DISTRIBUTOR TIMING ADVANCE Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Advance Unit > Component Information > Description and Operation > Vacuum Spark Advance Mechanism Distributor Advance Unit: Description and Operation Vacuum Spark Advance Mechanism The vacuum spark control mechanism can provide spark advance if a single diaphragm assembly is used or spark advance and retard if a dual diaphragm assembly is used. The diaphragm assembly used depends on the engine calibration. Single Diaphragm Assembly SINGLE DIAPHRAGM ASSEMBLY The single diaphragm assembly, Fig. 11, also changes the armature to stator relationship to give spark advance. The stator assembly position is changed by means of vacuum being applied to the diaphragm assembly. Vacuum applied to the diaphragm assembly causes the diaphragm and attached diaphragm rod to move, compressing the advance spring, which controls the rate of advance. The movement of the diaphragm rod, which is attached to the stator assembly, makes the the stator assembly move with respect to the armature. This changes the initial armature to stator relationship set during initial timing, causing spark advance. The stator assembly is mounted on the lower plate assembly which with the diaphragm assembly, is attached to the distributor base. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Advance Unit > Component Information > Description and Operation > Vacuum Spark Advance Mechanism > Page 412 Dual Diaphragm Assembly DUAL DIAPHRAGM ASSEMBLY The dual diaphragm assembly, Fig. 12, obtains spark advance in the same manner as the single diaphragm assembly. In this case vacuum applied to the vacuum advance port causes the advance diaphragm and attached rod to move, otherwise the action is the same. Spark retard is done by applying vacuum to the vacuum retard port. This causes the retard diaphragm to move, compressing the retard spring, which controls the rate of spark retard. Compressing the retard spring allows the diaphragm rod stop to move due to the force applied by the advance spring pushing against it by means of the diaphragm rod. The result is the diaphragm rod moves causing the attached stator assembly to change position with respect to the armature. In this instance the direction of the stator assembly movement is opposite that occurring during vacuum advance, resulting in spark retard. NOTE: Any vacuum applied to the advance port overrides any spark retard caused by vacuum being applied to the retard port. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Advance Unit > Component Information > Description and Operation > Vacuum Spark Advance Mechanism > Page 413 Distributor Advance Unit: Description and Operation Centrifugal Spark Advance Mechanism Distributor - Exploded view The centrifugal advance mechanism varies the relationship of the armature to the stator assembly. The armature is mounted to the sleeve and plate assembly which rotates in relation to the distributor shaft. The rotation is a result of the centrifugal weights moving in response to engine RPM. The movement of the weights change the initial relationship of the armature to the stator assembly by rotating the sleeve and plate assembly ahead of its static position on the distributor shaft Fig. 1. This produces spark advance. The rate of movement of the weights is controlled by calibrated springs. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Advance Unit > Component Information > Description and Operation > Page 414 Distributor Advance Unit: Service and Repair 1. Remove distributor cap and rotor. 2. Disconnect vacuum lines, then remove snap ring that secures vacuum advance link to pickup assembly. 3. Remove vacuum advance attaching screws, then tilt unit downward to disconnect link. 4. Carefully remove unit from distributor. 5. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Retard Control > Component Information > Locations Distributor Retard Control: Locations Below Vacuum Switch Between No. 5 & No. 6 Spark Plugs Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Vacuum Control > Component Information > Description and Operation Distributor Vacuum Control: Description and Operation 3-Port Vacuum Regulator Vacuum Regulator (3 & 4 Port) Three port, Fig. 27, regulators and four port, Fig. 28, regulators are used to control the vacuum advance to the distributor. During engine idle conditions, the manifold vacuum signal is reduced to a constant output signal. Off idle, the output signal equals the spark port. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Vacuum Control > Component Information > Testing and Inspection > Distributor Modulator Valve Assembly Distributor Vacuum Control: Testing and Inspection Distributor Modulator Valve Assembly 1. Turn ignition key to ``ON'' and check resistance at solenoid terminals. 2. If solenoid resistance is not 51---108 ohms, replace solenoid. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Vacuum Control > Component Information > Testing and Inspection > Distributor Modulator Valve Assembly > Page 423 Distributor Vacuum Control: Testing and Inspection Vacuum Regulator Procedure 1. Disconnect vacuum line from distributor port and connect a vacuum gauge. 2. With engine at idle, the vacuum gauge reading should be within 1 inch Hg. vacuum of the calibration point. The calibration point of each valve can be identified according to color code as follows: Black, 6 inches Hg.; green, 7 inches Hg.; red, 8 inches Hg. 3. Replace valve if not within specifications. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > Ignition Rotor - Alignment Procedure Ignition Rotor: Technical Service Bulletins Ignition Rotor - Alignment Procedure Article No. 83-8-14 EEC III/DISTRIBUTOR - PROCEDURE FOR SETTING ROTOR ALIGNMENT 5.0L/5.8L EEC EQUIPPED LIGHT TRUCKS LIGHT TRUCKS 1981/83 BRONCO, F-SERIES AND ECONOLINE The following information and procedures are issued to clarify the proper setting of distributor rotor alignment on the subject vehicles. This reference publication supersedes all other printed material on subject. FIGURE 12 FIGURE 13 For 1981 through 1983 model year vehicles, EEC distributors used on the EEC Systems had the "second generation" rotor (Figure 12). The 1983 model 5.0L EEC equipped Light Truck employs a conventional rotor (Figure 13). PROCEDURE FOR ROTOR ALIGNMENT: 1. Remove the distributor cap and wires and position them to one side. 2. Remove the rotor. 3. To check rotor alignment: a. Rotate the engine until the No. 1 piston is on the compression stroke. NOTE: Verification of being on the compression stroke is essential to correct rotor alignment. If the piston is on the exhaust stroke, the rotor can be misaligned by 180~. b. Slowly rotate the engine until the alignment tool can be installed. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > Ignition Rotor - Alignment Procedure > Page 428 FIGURE 14 c. The T79P-12200-A tool mounts between the slot on the sleeve and the slot (cut out) on the adapter (Figure 14). d. Read the timing mark on the damper indicated by the timing pointer. e. If the timing mark is specification, TDC +/- 4~, the rotor alignment is satisfactory. The alignment tool can be removed. TO ADJUST ROTOR ALIGNMENT: 1. Remove the distributor cap by loosening the two spring clips holding the cap of the distributor adapter. Remove rotor. 2. Rotate engine until No. 1 piston is on the compression stroke. (See Step 3a above). 3. Slowly rotate the engine until the timing pointer is aligned with the specified timing mark. (TDC +/- 4~). 4. Loosen the two sleeve assembly adjustment screws and rotate the sleeve until the alignment tool T79PFIGURE 14 12200-A fits into the alignment slots on the sleeve and the adapter (Figure 14). 5. Tighten the adjustment screw to 2.8-3.9 N-m (25-30 lb.in.). Remove alignment tool. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > Ignition Rotor - Alignment Procedure > Page 429 FIGURE 13 6. If the vehicle is a 1983 model equipped with a 5.0L engine, coat the rotor with silicone grease as shown in Figure 13. 7. Reinstall distributor cap and rotor making sure wires are firmly seated in the distributor cap terminal housings and on the spark plugs. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Plate W/ Pick-up Sensor > Component Information > Service and Repair Distributor Plate W/ Pick-up Sensor: Service and Repair 1. Remove distributor cap and rotor. 2. Remove vacuum advance unit and magnetic pickup assembly. 3. Remove attaching screws and lift base plate from distributor. 4. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Vacuum Spark Delay Valve > Component Information > Description and Operation Vacuum Spark Delay Valve: Description and Operation Fig.25 - Spark Delay Valve This unit is used in conjunction with some of the other Ford systems. Its purpose is to further reduce emissions by delaying the spark advance during rapid acceleration and by cutting off advance immediately upon deceleration. Fig. 25. This plastic disc-shaped valve is installed in the carburetor vacuum line at the distributor advance diaphragm. It is a one way valve and will not operate if installed backwards. The black side of the valve must be toward the carburetor. This valve cannot be repaired. NOTE: On all systems which employ the dual diaphragm distributor the line which has high vacuum at idle (normal operating temperature) is connected to the secondary (retard) side of the distributor vacuum advance unit. This is the connection closest to the distributor cap. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Vacuum Spark Delay Valve > Component Information > Description and Operation > Page 436 Vacuum Spark Delay Valve: Testing and Inspection Fig.36 - SDV Valve Color Coding Fig.37 - Spark Delay Valve (SDV) Specifications Chart Refer to Figs. 36 & 37 for number value by color code. NOTE: To perform the following procedure, an external vacuum source capable of maintaining a minimum constant 10 inches Hg. is required. Mono Delay Valve 1. Set external vacuum source to 10 inches Hg. and connect black side of delay valve to vacuum source. 2. Connect a vacuum gauge with a 24 inch hose to colored side of delay valve. 3. Apply 10 inches Hg. vacuum and observe time in seconds for gauge to read 0-8 inches Hg. The minimum and maximum time for gauge to read 8 inches Hg. should be as shown in Fig. 37. Dual Delay Valve 1. Set external vacuum source to 10 inches Hg. and connect vacuum gauge with a 24 inch hose to DIST nipple of delay valve. 2. Connect black side of delay valve and CARB nipple of delay valve to vacuum source. NOTE: Avoid applying vacuum to CARB nipple while applying vacuum to black side of valve. 3. Apply 10 inches Hg. of vacuum and observe time in seconds for gauge to read from 0-8 inches Hg. The minimum and maximum time for gauge to read 8 inches Hg. should be as shown in Fig. 37. Retard Delay Valve 1. Set external vacuum source to 10 inches Hg. and connect colored side of delay valve to vacuum source. 2. Connect a vacuum gauge with a 24 inch hose to white side of delay valve. 3. Apply 10 inches Hg. of vacuum and observe time in seconds for gauge to read from 0-8 inches Hg. The minimum and maximum time for gauge to read 8 inches Hg. should be as shown in Fig. 37. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications SPARK PLUGS Gap ...................................................................................................................................................... ............................................................ 0.044 in Torque ...................................................................... ............................................................................................................. 14-20 Nm (10-15 ft-lbs) Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 440 Spark Plug: Service and Repair REMOVAL - Remove the wire from each spark plug by grasping the molded boot with tool T74P-6666-A or equivalent. Twist the boot until it loosens and then pull it off the spark plug. Do not pull on the wire, as the connection may become damaged. - Any wire damaged must be replaced. Each original spark plug wire is numbered for the cylinder to which it is designated. If wires are not numbered, each wire should be numbered as to the plug from which it was removed. - Clean the area around each spark plug port with compressed air. - Using the proper size spark plug socket remove the spark plugs. INSTALLATION Check the gap on each new spark plug and set to specification. See: Specifications Cylinder Numbering And Distributor Location - Install each spark plug and tighten to 14-20 Nm (10-15 ft-lbs). - Coat the inside of each spark plug boot with silicone dielectric compound. Connect each spark plug wire to the plug from which it was removed. Be sure each wire is fully depressed on each plug and molded boot is firmly in place. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis Compression Check: Testing and Inspection COMPRESSION TEST 1. Ensure oil in crankcase is of the correct viscosity and at proper level and battery is properly charged. Operate vehicle until engine is at normal operating temperature. Turn OFF ignition switch, then remove all spark plugs. 2. Set throttle plates (and choke plates, if equipped) in wide-open position. 3. Install a compression gauge such as Rotunda Compression Tester 059-00009 or equivalent in No. 1 cylinder. 4. Install an auxiliary starter switch in starting circuit. With ignition switch in the OFF position, and using auxiliary starter switch, crank engine at least five compression strokes and record highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat test on each cylinder cranking the engine approximately the same number of compression strokes. TEST CONCLUSION 1. The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest. 2. If one or more cylinders read low, squirt approximately one tablespoon of heavy SAE 50 weight or equivalent engine oil on top of the pistons in the low reading cylinders. Repeat compression pressure check on these cylinders. a. If compression improves considerably, piston rings are at fault. b. If compression does not improve, valves are sticking or seating poorly. c. If two adjacent cylinders indicate low compression pressures and squirting oil on pistons does not increase compression, cause may be a cylinder head gasket leak between cylinders. Engine oil and/or coolant in cylinders could result from this problem. Compression Pressure Limit Chart NOTE: Refer to the compression pressure limit chart for pressure specifications. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications ENGINE YEAR CLEARANCE V6-232 82-83 .088-.189 V8-255 81-82 .123-.173 6-300 80-87 .125-.175 V8-302 80-87 .096-.165 V8-351M 80-81 .125 V8-351W 80-87 .123-.173 V8-400 80-82 .175 V8-460 80-87 .100-.150 On engines with hydraulic lifters, clearance specified is at valve stem tip with lifter collapsed. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 447 Valve Clearance: Locations FRONT TO REAR 6-300 E-I-E-I-E-I-E-I-E-I-E-I V6-232 Right I-E-I-E-I-E V6-232 Left E-I-E-I-E-I V8-255, 302 Left Bank E-I-E-I-E-I-E-I V8-255, 302 Right Bank I-E-I-E-I-E-I-E V8-351, 400 Right Bank I-E-I-E-I-E-I-E V8-351, 400 Left Bank E-I-E-I-E-I-E-I V8-460 Left Bank E-I-E-I-E-I-E-I V8-460 Right Bank I-E-I-E-I-E-I-E Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 448 Valve Clearance: Adjustments Fig. 21 Compressing valve lifter with tool to check clearance on engines with hydraulic valve lifters V8 ENGINES To provide a means to compensate for dimensional changes in the valve train and provide for valve adjustment, .060 inch shorter or longer pushrods are available. If the valve clearance is less than the minimum, the .060 inch shorter pushrod should be used. If the clearance is more than the maximum, the longer pushrod should be used. To check the valve clearance, proceed as follows: 1. Mark crankshaft pulley at three locations, with No. 1 location at TDC timing mark (end of compression stroke), location No. 2 one full turn (360°) clockwise from TDC and No. 3 location one quarter turn clockwise (90°) from position No. 2. 2. Turn crankshaft to number 1 location, then compress valve lifter using tool T71P-6513-A or equivalent, Fig. 21, and check the clearance on the following valves: V8-255, 302, 460 No. 1 Intake No. 1 Exhaust No. 7 Intake No. 5 Exhaust No. 8 Intake No. 4 Exhaust V8-351 & 400 No. 1 Intake No. 1 Exhaust No. 4 Intake No. 3 Exhaust No. 8 Intake No. 7 Exhaust 3. Turn crankshaft to number 2 location, then compress valve lifter using tool T71P-6513-A or equivalent, Fig. 21, and check the clearance on the following valves: V8-255, 302, 460 No. 5 Intake No. 2 Exhaust No. 4 Intake No. 6 Exhaust V8-351 & 400 No. 3 Intake No. 2 Exhaust No. 7 Intake No. 6 Exhaust 4. Turn crankshaft to number 3 location, then compress valve lifter using tool T71P-6513-A or equivalent, Fig. 21, and check the clearance on the following valves: V8-255, 302, 460 No. 2 Intake No. 7 Exhaust No. 3 Intake No. 3 Exhaust No. 6 Intake No. 8 Exhaust V8-351 & 400 No. 2 Intake No. 4 Exhaust No. 5 Intake No. 5 Exhaust No. 6 Intake No. 8 Exhaust Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications Drive Belt: Specifications A belt in operation 10 minutes is considered a used belt. 1988-89 Automatic tensioner used. Deflection method: Table lists deflection at midpoint of belt segment. Strand Tension method: Use a strand tension gauge. Measurements are in pounds. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Specifications > Page 452 Drive Belt: Adjustments A belt in operation 10 minutes is considered a used belt. 1988-89 Automatic tensioner used. Deflection method: Table lists deflection at midpoint of belt segment. Strand Tension method: Use a strand tension gauge. Measurements are in pounds. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Component Information > Technical Service Bulletins > Air Cleaner - Sealing Procedure Air Cleaner Housing: Technical Service Bulletins Air Cleaner - Sealing Procedure Article No. 83-25-21-S AIR CLEANER SEALING - 4.9L (1982-83 F-SERIES AND BRONCO ONLY) AND ALL UNITS WITH 5.0L, 5.8L OR 7.5L ENGINES. UNITS OPERATED IN DUSTY AND/OR OFF-ROAD CONDITIONS ARTICLE ALSO INCLUDES SEALING OF 7200VV CARBURETOR ON UNITS SO EQUIPPED LIGHT TRUCKS 1980-83 E, F AND BRONCO This is a re-write of TSB 83-25-21 (December 12, 1983). The air cleaner part numbers listed in the TSB are of insufficient detail and are therefore being deleted from the TSB. Due to the variety of different air cleaners used, part numbers have not been included in this TSB. See your normal parts listing for these part numbers. The subject vehicles operated in dusty/off-road conditions may experience an air cleaner sealing concern which could lead to engine oil consumption or, on 7200 VV carburetor equipped vehicles, a poor running condition. The following procedure should minimize these concerns. 1. Remove the air cleaner assembly from the engine and remove any loose debris from inside the tray. Replace the air cleaner assembly (9600) on all 1983 4.9L, 5.0L, 5.8L and, 7.5L equipped light trucks except the 1983 Econoline with the 4.9L engine. Due to the variety of different air cleaners used, part numbers have not been included in this TSB. See your normal parts listings for these part numbers. 2. Wipe the sealing surfaces clean on the tray and cover and inspect for any dents or damage that would prevent a good seal. Replace any damaged components. 3. Inspect the air cleaner to carburetor gasket for proper installation. If the gasket appears crimped or damaged, replace it with a new sticky-back gasket. Prior to replacing the gasket, clean the carburetor flange. Install the new gasket sticky side down and press all the gasket down to assure a tight bond. Gasket parts numbers: 4.9L - C8DZ-9654-A, 5.0L/5.8L/7.5L - D8ZZ-9654-A. FIGURE 24 4. For F-Series and Bronco only, relocate the zip tube inlet. a) Detach the zip tube inlet from the radiator support. b) Move the inlet to the top rear of the wheel wellhousing per Figure 24. c) Secure the zip tube to the top of the housing with a nylon tie-down strap. NOTE: At high temperatures, an octane ping may occur. If it persists, the zip tube must be reinstalled to the radiator support. 5. Replace the PCV filter. For 4.9L, 5.0L-2V, 5.8L-2V and 7.5L-4V engines replace the PCV filter in the air cleaner with an in-line filter. a. Remove and discard the crankcase breather cap to PCV filter hose (closure hose), PCV filter in the air cleaner, the adapter at the air cleaner and the adapter retaining clip. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Component Information > Technical Service Bulletins > Air Cleaner - Sealing Procedure > Page 458 b. Drill a 5/16" hole in the side wall of the air cleaner approximately 12" to the rear of the existing crankcase closure hole for 5.0L and 5.8L and approximately 6" to the rear on 7.5L. (The 4.9L does not need a new hole). c. Install a 1/2" hose (E2AZ-6853-A) to the existing adaptor in the valve cover oil fill cap (2 pcs. 2-5/8" long for 4.9L, 18" long for 5.0L/5.8L, 12" long for 7.5L). d. At a convenient location, cut the hose and install an in-line filter E2AZ-6A768-A for 5.0L, 5.8L and 7.5L. On the 4.9L, install the filter between the 2-5/8" long pieces installed in (c.). NOTE: Install the filter with the wire mesh toward the oil fill cap. The mesh can be seen by looking into the end of the filter assembly. e. Install an adapter E43Z-9E606-A in the air cleaner and attach using a retaining clip 383741-S. Center the adapter elbow in the new hole for 5.0L, 5.8L and 7.5L. Use the existing PCV filter (closure) pack hole for 4.9L. f. Cut the PCV filter (closure) hose to proper length and attach to the adapter. g. Plug the old hole in the tray with plug 377678-S for 5.0L, 5.8L and 7.5L only. FIGURE 25 6. For 5.0L and 5.8L engines with a 7200 VV carburetor, clean and seal the carburetor to prevent dirt migration through the choke rod and accelerator pump rod holes (Refer to Figure 25). a. Remove the carburetor from the vehicle. b. Without disassembling the carburetor, thoroughly clean with Ford Automatic Choke Cleaner or equivalent, all of the choke linkage and accelerator pump linkage on the top and sides of the carburetor. Pay particular attention to the top and bottom of the upper body casting around the choke and accelerator pump rods. Allow cleaner to evaporate or blow dry with shop air. c. Remove stepper motor, gasket, pintle and spring. Clean pintle and pintle cavity in main body casting thoroughly with Ford Automatic Choke Cleaner or equivalent. Do not re-install stepper motor at this time. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Component Information > Technical Service Bulletins > Air Cleaner - Sealing Procedure > Page 459 FIGURE 24 d. Hold throttle lever in the wide-open throttle position to raise the accelerator pump rod. With a toothpick, or other sharp tool, apply any commercially available silicone RTV (such as Dow Corning "Silastic") to the top side of the upper body casting around the accelerator pump rod (Figure 24). Fill the hole completely around the rods from the top side only and release the throttle lever. e. With a rubber band, tie the throttle lever in closed-throttle position. Push fast idle cam to "off" position so that choke rod is fully raised. Fast idle cam should remain in "off" position. f. With a toothpick, apply silicone RTV to bottom side of upper body casting around the choke shaft rod. Fill the hole completely around the rod from the bottom side only. g. Install the spring, pintle, gasket, and stepper motor. h. Allow carburetor to stand at room temperature for 24 hours without disturbing silicone RTV. i. After 24-hour cure, remove rubber band from throttle lever, and open throttle to break (free) accelerator pump rod from silicone RTV. Bulk of RTV sealant should remain attached to upper body. j. Manually exercise choke linkage to break (free) choke rod from silicone RTV. Bulk of RTV sealant should remain attached to upper body. k. Re-install carburetor on vehicle. 7. Re-install and secure the air cleaner assembly as follows: a. Set the air cleaner tray assembly on the carburetor and check that nothing is preventing the tray seating securely and completely sealing the flange. b. Connect and secure the vacuum hoses. c. Install and seat a new heavy duty air cleaner element in the tray. Use E2TZ-9601-B (FA-732) for 4.9L and E0TZ-9601-A (FA-688) for 5.0L/5.8L. Use non-heavy duty element for 7.5L. NOTE: Use of incorrect element will allow dirt to be ingested and will damage the engine. d. Install the air cleaner cover and place the washer grommet rubber side down. Torque the wing nut hand tight (20 in.lbs.). Try to rotate the air cleaner assembly slightly. If it resists rotation, sealing to the carburetor is assured. e. Connect the crankcase filter hose securely. f. Install the heat riser tube. Connect the fresh air zip tube. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Component Information > Technical Service Bulletins > Air Cleaner - Sealing Procedure > Page 460 Obtain an Authorized Modifications decal and list the date, dealer number and summary of alterations performed. Select a prominent place adjacent to the Vehicle Emission Control Information decal suitable for installing the Authorized Modifications decal. Clean the area, install the decal and cover it with a clear plastic decal shield. PART NUMBER PART NAME CLASS E2AZ-6A768-A PCV Filter C E2AZ-6853-A 1/2" PCV Hose C E43Z-9E606-A Adapter C E2TZ-9601-B Air Filter Element AM E0TZ-9601-A Air Filter Element AM C6TZ-9697-A Washer AM D8ZZ-9654-A Gasket A 377678-S Plug BR E3AZ-19562-A RTV Sealer A 390013-S36B Wing Nut S C8DZ-9654-A Gasket AM OTHER APPLICABLE ARTICLES: 83-25-21 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP9600C84 TIME: 6 cyl. - 0.5 Hr. 8 cyl. - 1.1 Hrs. DLR. CODING: Basic Part No. 9600 Code: 49 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Filters > Air Injection Filter > Component Information > Service and Repair Air Injection Filter: Service and Repair Fig. 68 Removing centrifugal type air pump filter Centrifugal Filter Fan, Replace 1. Remove drive pulley and outer disc from air pump. 2. Remove filter fan from pump, Fig. 90. NOTE: Do not attempt to remove the metal drive hub. 3. Install new filter fan using the pulley and bolts. Alternately tighten bolts to draw fan down evenly. NOTE: A slight interference between the fan and housing is normal. A new fan may make noise during initial operation, until it's outer diameter sealing lip has worn in, after approximately 20-30 miles of operation. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Technical Service Bulletins > Fuel Filter - Replacement Information Fuel Filter: Technical Service Bulletins Fuel Filter - Replacement Information Article No. 85-6-10 FUEL FILTER REPLACEMENT INFORMATION - ALL WITH FUEL FILTERS ATTACHED TO THE CARBURETOR AND/OR FUEL LINE WITH A RUBBER HOSE FORD ALL 1985 AND PRIOR LINCOLN-MERCURY ALL 1985 AND PRIOR LIGHT TRUCK ALL 1985 AND PRIOR New fuel connector hoses and clamps should be used whenever a fuel filter is replaced. Due to possible deterioration of hose materials which may result if a vehicle is fueled with gasoline containing excessive levels of methanol or ethanol, a new fuel hose and clamps should be installed when the fuel filter is changed. DO NOT REUSE OLD HOSES OR CLAMPS. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Service and Repair > Screw In Type Fuel Filter: Service and Repair Screw In Type REMOVAL 1. Remove the air cleaner assembly. 2. Loosen and remove the fuel tube from the filter. 3. Unscrew the filter from the carburetor. INSTALLATION 1. Apply one drop of thread sealer to the external thread of a new filter. Thread the filter into the carburetor inlet port. 2. Tighten the filter to 9.0-11.0 Nm (80-100 in-lbs). 3. Apply ESE-M2C39-E or equivalent oil to the fuel supply tube nut and flare , and hand start the nut into the fuel filter inlet approximately two threads. 4. Use an 11/16 inch wrench on the fuel filter to prevent the filter from rotating. Tighten the fuel filter to supply tube nut to 20-24 Nm (15-18 ft-lb). 5. Install air cleaner assembly. 6. Start the engine and check for fuel leaks. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Component Information > Service and Repair > Screw In Type > Page 470 Fuel Filter: Service and Repair Inlet Fitting Type REMOVAL - Remove the air cleaner. - Hold the fuel filter inlet hex nut with a backup wrench and unscrew the fuel line tube nut from the fuel filter inlet. WARNING: Use care to prevent combustion from fuel spillage. - Unscrew the fuel inlet fitting. Remove the gasket, filter and spring. - Discard the gasket and filter. INSTALLATION - Install the spring, new filter and gasket. - Hand start the fuel inlet fitting into the carburetor then, tighten to 10-24 Nm (90-125 lb-in). - Apply oil, ESE-M2C39-E or equivalent to the fuel tube nut threads and tube flare. - Hand start the fuel line tube nut into the fuel inlet fitting (approximately two threads). - Use a backup wrench on the fuel inlet fitting while tightening the fuel line tube nut to 20-24 Nm (15-18 lb-ft). - Start the engine and check for fuel leak. - Install the air cleaner. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement Technical Service Bulletin # 98-12-5 Date: 980622 A/C - Filtering Refrigerant After Compressor Replacement Article No. 98-12-5 06/22/98 AIR CONDITIONING - FILTERING REFRIGERANT AFTER A/C COMPRESSOR REPLACEMENT - SERVICE TIPS FORD: 1980-98 CROWN VICTORIA 1981-98 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-97 THUNDERBIRD 1982-98 MUSTANG 1983-86 LTD 1984-94 TEMPO 1986-98 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-98 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1980-98 GRAND MARQUIS, TOWN CAR 1982-83 ZEPHYR 1982-86 CAPRI 1982-87 LN7 1982-97 COUGAR 1982-98 CONTINENTAL 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-98 SABLE 1991-94 CAPRI 1991-98 TRACER 1993-98 MARK VIII 1995-98-MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1980-96 BRONCO 1980-97 F SUPER DUTY 1980-98 ECONOLINE, F-150, F-150, F-350 1983-98 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F-47 1991-98 EXPLORER 1993-98 VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to revise the Service Procedure and to update the model years. ISSUE Vehicles that have and inoperative A/C compressor, due to internal causes, MUST have the refrigerant system cleaned to remove any debris or contaminants that may be present to prevent damage to the replacement compressor. ACTION Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 475 Install a Service Filter Kit in the refrigerant system prior to installing the replacement compressor. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-15-5 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-99 Models And 1991 Lincolns, Basic Warranty Coverage For All Other Models And Major Component Warranty Coverage For All Other Lincoins OPERATION DESCRIPTION TIME 981205A Kit Installation 1.2 Hrs. 981205B Extra Time For Refrigerant 0.4 Hr. (R-12) Recovery DEALER CODING CONDITION BASIC PART NO. CODE 19703 49 OASIS CODES: 208000, 208999 Service Procedure THIS PROCEDURE IS OPTIONAL IF THE SYSTEM IS FLUSHED USING THE ROTUNDA A/C FLUSHER. CAUTION THIS FILTERING PROCEDURE MAY BE USED FOR EITHER R-12 OR R-134a REFRIGERANT SYSTEMS. BECAUSE THE TWO (2) SYSTEMS USE DIFFERENT REFRIGERANT OILS AND BECAUSE THE COMPRESSOR COULD BE DAMAGED IF THE WRONG OIL IS USED, SYSTEM IDENTIFICATION IS VERY IMPORTANT. BE SURE SYSTEM IS CORRECTLY IDENTIFIED BEFORE STARTING THE FILTERING PROCEDURE. Each Service Filter Kit includes the following items: ^ One (1) Pancake Filter (to be installed in the liquid line between the condenser and the orifice tube) ^ One (1) Instruction Sheet NOTE ON 1993-94 RANGER/EXPLORER VEHICLES, TECHNICIANS MAY EXPERIENCE DIFFICULTY WHEN CONNECTING THE PANCAKE FILTER HOSE FITTINGS TO THE EVAPORATOR INLET WITH THE ORIFICE TUBE INSTALLED. REMOVE THE OFFICE TUBE AND RUN THE SYSTEM FOR 1 HOUR AS DESCRIBED IN THE FILTERING PROCEDURE. REINSTALL THE ORIFICE TUBE AFTER FILTERING IS COMPLETE. CAUTION FOLLOW ALL REFRIGERANT SYSTEM SAFETY AND SERVICE PRECAUTIONS OUTLINED IN THE APPROPRIATE SERVICE OR WORKSHOP MANUAL. 1. Before removing any refrigerant system components, recover the refrigerant from the system following the recycling methods outlined In the appropriate Service/Workshop Manual. 2. Remove the suction accumulator/drier assembly and drain the oil into a calibrated container. 3. Install a new suction accumulator/drier and add new refrigerant oil to replace the old oil. The quantity of the new oil to be added is the amount to match that drained from the old accumulator plus 60 mL (2 oz). Refer to the Dealer Master Parts Catalog for the correct suction accumulator/drier part number. CAUTION REMEMBER TO USE MOTORCRAFT YN-9-A REFRIGERANT COMPRESSOR OIL WITH R-12 SYSTEMS AND MOTORCRAFT YN-12-C REFRIGERANT COMPRESSOR OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. 4. Install a new orifice tube. Refer to the Dealer Master Parts Catalog for the correct orifice tube part number. If the orifice tube in the vehicle is located in the liquid line between the condenser and the evaporator, replace the liquid line assembly. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 476 5. Install pancake filter in the liquid line between the condenser and the orifice tube, Figure 1. a. Be sure orifice inlet is toward the condenser. b. Connections can be made using Test Adapter Set D93L-19703-B, or equivalent, and flexible refrigerant hose of 2500 psi burst rating. Individual fittings are also available. 6. Remove the old compressor following Service/Workshop Manual procedures. Drain the oil into a calibrated container. 7. Drain the oil from the replacement compressor into a clean calibrated container. NOTE: IT WILL BE NECESSARY TO TRANSFER THE MAGNET CLUTCH FROM THE OLD COMPRESSOR TO THE REPLACEMENT COMPRESSOR. FOLLOW SERVICE/WORKSHOP MANUAL PROCEDURES. 8. A new FX-15 service compressor contains 207 mL (7 oz.) of R-12 refrigerant oil. A new FS-10 service compressor does not contain any oil and can be used with an R-12 or an R-134a system. CAUTION REMEMBER TO USE YN-9-A (MINERAL) OIL WITH R-12 SYSTEMS AND YN-12-C (PAG) OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. ^ If the amount of oil drained from the removed compressor is between 90 and 148 mL (3-5 oz), pour the same amount of clean refrigerant oil into the new compressor. ^ If the amount of oil drained from the old compressor is greater than 90 mL (3 oz), pour 90 mL (3 oz) of clean refrigerant oil into the new compressor. 9. Install the new compressor following Service/Workshop Manual procedures. Make sure all mounting bolts are tightened properly. Check the tension of the compressor drive belt. Adjust if necessary. 10. Evacuate, charge and leak test the system, following Service/Workshop Manual procedures. 11. Check all refrigerant system hoses, lines and the position of the newly-installed filters to make sure they do not interfere with other engine compartment components. If necessary, use tie straps to make adjustments. 12. Set the A/C control on Max A/C, high blower and temperature control at full cold. a. Start engine and let idle briefly. b. Be sure A/C system is operating properly. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 477 13. Gradually bring the engine up to 1200 rpm by running it at lower rpms for short periods (first at 800 rpm, then at 1000 rpm). Set the engine at 1200 rpm and run it for an hour with the A/C system operating. 14. Stop the engine. NOTE: IT WILL BE NECESSARY TO RECOVER THE SYSTEM REFRIGERANT CHARGE BEFORE PROCEEDING. 15. Allow the engine to cool sufficiently to remove the fittings, flexible hoses and pancake filter from the liquid line. 16. Discard the filter. It can be used one (1) tie only. 17. Reconnect the liquid line back into the system. 18. Evacuate, charge and leak test the system. Make any necessary adjustments. 19. Check the operation of the system in all models. PART NUMBER PART NAME F8VZ-19E773-AA Filter Kit F73Z-19577-AA Refrigerant Oil - Motorcraft YN-9-A (For R-12 Refrigerant Systems Only) F7AZ-19589-DA Refrigerant Oil - Motorcraft YN-12-C (PAG-Type Oil For R-134a Refrigerant Systems Only) NOTE THE TOTAL REPAIR TIME IS FOR INSTALLING SERVICE FILTER KIT PER INSTRUCTIONS THIS INCLUDES INSTALLATION OF AND DISCARD OF FILTER. REFER TO SERVICE LABOR TIME STANDARDS MANUALS IF ADDITIONAL LABOR OPERATIONS ARE REQUIRED. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Hoses > System Information > Service Precautions Hoses: Service Precautions SERVICE PRECAUTIONS To prevent vehicle damage, always observe the following precautions: After servicing a hose, check for leaks before and after test driving the vehicle. - Always use the correct size hose. Do not use standard sized hose in place of metric hose or vice versa. Always use the correct type of hose. Never use vacuum hose in place of fuel hose. Never use heater hose in place of PCV hose. - When replacing hoses which are attached to the engine on one end and the frame or body on the other end, always leave sufficient length to compensate for engine movement (from torque). Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recycled Engine Coolant - Service Tips Coolant: Technical Service Bulletins Recycled Engine Coolant - Service Tips Article No. 95-18-2 09/11/95 ^ COOLANT - USE OF RECYCLED ENGINE, COOLANT - SERVICE TIP ^ COOLING SYSTEM - USE OF RECYCLED ENGINE, COOLANT - SERVICE TIP FORD: 1980 and after CROWN VICTORIA, MUSTANG, THUNDERBIRD 1981 and after ESCORT 1982-88 EXP 1984-94 TEMPO 1986 and after TAURUS 1988-93 FESTIVA 1989 and after PROBE 1994 and after ASPIRE 1995 and after CONTOUR LINCOLN-MERCURY: 1980 and after CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1981-86 CAPRI 1981-87 LYNX 1984-92 MARK VII 1984-94 TOPAZ 1986 and after SABLE 1987-89 TRACER 1991-94 CAPRI 1991 and after TRACER 1993 and after MARK VIII 1995 and after MYSTIQUE MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1980 and after F-150-350 SERIES 1981 and after ECONOLINE 1982 and after BRONCO 1983 and after RANGER 1984-90 BRONCO II 1986 and after AEROSTAR 1988 and after F SUPER DUTY 1991 and after EXPLORER 1993 and after VILLAGER 1995 and after WINDSTAR This TSB is being republished in its entirety to include warranty information when using recycled coolant ISSUE: Ford Motor Company authorizes the use of recycled engine coolant that, when properly processed and reinhibited, meets Ford specification ESE-M97B44-A. At this time, the Rotunda Coolant Recycler (181-00003) process is the only approved coolant recycling method available through Ford that is capable of producing recycled engine coolant that meets Ford specification ESE-M97B44-A. ACTION: Refer to the following Service Procedure for coolant processing and reinhibiting using Rotunda Coolant Recycler (181-00003). NOTE: WHILE TESTING SHOWS THAT RECYCLED ENGINE COOLANT CAN PROVIDE ACCEPTABLE PERFORMANCE, THE COOLANT PRODUCED FROM ROTUNDA EQUIPMENT IS INTENDED FOR USE WITHIN DEALERSHIPS ON WARRANTY AND CUSTOMER PAY REPAIRS ONLY AND NOT INTENDED FOR RETAIL SALE. THERE ARE REGULATORY, PACKAGING AND LABELING CONCERNS Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recycled Engine Coolant - Service Tips > Page 486 ASSOCIATED WITH THE RETAIL SALE OF CHEMICAL PRODUCTS. CAUTION: THE REINHIBITOR CHEMICALS PROVIDED WITH THIS EQUIPMENT ARE NOT APPROPRIATE FOR USE ON MEDIUM/HEAVY TRUCK APPLICATIONS. WARNING: ROTUNDA PREMIUM COOLANT REINHIBITORS # 1 AND # 2 HAVE BEEN SPECIFICALLY FORMULATED TO WORK WITH ROTUNDA COOLANT RECYCLER (181-00003). USE OF ANY OTHER CHEMICAL ADDITIVES WITH THIS SYSTEM WILL VOID ALL WARRANTIES FOR THE EQUIPMENT AND FOR THE FINAL COOLANT PRODUCT. SERVICE PROCEDURE DIRECTIONS FOR PROCESSING USED ENGINE COOLANT WITH ROTUNDA COOLANT RECYCLER 1. Close the drain valve on the unit. 2. Open the fill valve. 3. Pour used engine coolant into the funnel on the side of the unit. NOTE: MAXIMUM CAPACITY 15 25 GALLONS (95 L). 4. Insert the outlet hoses of the recycler into clean, properly labeled containers. One (1) container is for the outlet process water and the other container is for distilled ethylene glycol. 5. Push the "ON" switch on the front to start the operation. The unit will process 1 gallon (3.8 L) per hour of operation and will automatically shut off when cycle is complete. 6. Add reinhibitor following the directions in this article. 7. Open the drain valve to drain the residue from the distillation vessel. Dispose of residue in accordance with all local. state and federal regulations. ADDING REINHIBITOR CHEMICALS 1. Process the coolant according to the directions listed in this article 2. Thoroughly mix 4 fl oz (118 ml) of Reinhibitor # 1 to each gallon of distilled ethylene glycol. 3. Thoroughly mix 4 fl oz (118 ml) of Reinhibitor # 2 to each gallon of distilled ethylene glycol. 4. Mix well. 5. Check the pH level of the coolant. The pH level must be between 9 and 11. 6. Add enough water to the concentrated coolant to produce a 50/50 mixture of coolant and water. NOTE: THE CONCENTRATED COOLANT MUST BE MIXED WITH WATER TO MEET THE NECESSARY ENGINE FREEZE PROTECTION. 7. Check the coolant freeze point of the 50% coolant solution. Freeze point should be -34°F (-37°C). Consult the Rotunda Coolant Recycler Manual for more detailed operating instructions. Call 1-800-ROTUNDA, 8 AM to 8 PM EST, for inquiries regarding the Rotunda Coolant Recycler and to order the Reinhibitor (187-R0001). PART NUMBER PART NAME Rotunda # 187-R0001 Rotunda Premium Coolant Reinhibitor WARRANTY CLAIMS: Dealer can claim recycled engine coolant by Ford approved process via a warranty repair on an 1863 claim as follows: Part Number: RECCOOL (not a valid part number, but it is recognized on an 1863 claim). Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Recycled Engine Coolant - Service Tips > Page 487 Quantity: Indicate the number of QUARTS of recycled coolant used. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 95-16-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Less A/C System Capacity Note: E-100-150 exc. super cooling & E-250-350 with standard cooling, 20qts.; E-100-150 with super cooling & E-250-350 with heavy duty cooling, 21 qts.; E-250-350 with super cooling, 28 qts. With A/C System Capacity 21 qt (US) Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 490 Coolant: Fluid Type Specifications COOLING SYSTEM FLUID, PREMIUM Ford Part No. U.S.A (Except Oregon) ............................................................................................................................................................ E2FZ-19549-AA or -B Canada ............................................................................................................ .............................................................................................. CXC-8-B Oregon .................................. ............................................................................................................................................................. F5FZ-19549-CC Ford Specification ................................................................................................................................ ................................................... ESE-M97B44-A COOLING SYSTEM FLUSH Ford Part No. ....................................................................................................................................... ................................................... F1AZ-19A503-A Ford Specification ................................................. ..................................................................................................................................... ESR-M14P7-A Coolant Mixture with Water ................................................................................................................. ...................................................................... 50% Warning: Do not mix coolant types. Check the owners manual or refer to your local dealer for the correct coolant type. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 861117 > Jun > 86 > A/T - Synthetic Fluid Availability Fluid - A/T: Customer Interest A/T - Synthetic Fluid Availability Article No. 86-11-17 TRANSMISSION - AUTOMATIC - NEW SYNTHETIC DEXRON II ALL WEATHER AUTOMATIC TRANSMISSION FLUID FORD 1986 and PRIOR ESCORT, EXP, FORD, LTD, THUNDERBIRD, MUSTANG, TEMPO; 1986 TAURUS LINCOLN-MERCURY 1982-83 LN7; 1986 and PRIOR LYNX, MERCURY, MARQUIS, COUGAR, CAPRI, TOPAZ, LINCOLN, MARK, CONTINENTAL; 1986 SABLE LIGHT TRUCK 1986 and PRIOR E, F SERIES, BRONCO, BRONCO II, RANGER A new synthetic Dexron II automatic transmission fluid specification number ESR-M2C163-A2, part number E6AZ-19582-B is now available. This fluid will maintain a more constant viscosity through a wider range of temperatures. In the event a vehicle will be operated in extremely cold temperatures for an extended period of time, remove all existing fluid from the transmission (using the procedure shown in the applicable 1986 Car or Light Truck Shop Manual) and replace with the new synthetic Dexron II fluid, E6AZ-19582-B. The synthetic fluid is year 'round fluid and will not require replacement for warmer weather. CAUTION: DO NOT use synthetic Dexron II fluid in transmissions designed to use Type "F" fluid. PART NUMBER PART NAME CLASS E6AZ-19582-B Synthetic Dexron Oil V Automatic Transmission Oil OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 06-14-4 > Jul > 06 > A/T - Mercon V ATF Usage Fluid - A/T: All Technical Service Bulletins A/T - Mercon V ATF Usage TSB 06-14-4 07/24/06 MERCON ATF IS BEING REPLACED BY MERCON V ATF AS A SERVICE FLUID. FORD: 1980-1997 Crown Victoria 1981-1997 Mustang, Thunderbird 1981-2003 Escort 1986-1993 Festiva 1986-1997 Taurus 1989-1997 Probe 1994-1997 Aspire 1995-2000 Contour 1980-1996 Bronco 1981-2003 F-150 1981-2004 E-Series, F-Super Duty 1983-1996 Ranger 1986-1996 Aerostar 1991-1997 Explorer 1993-2004 F-53 Motorhome Chassis 1995-1998 Windstar 1997-2004 Expedition 2000-2005 Excursion 2001-2007 Escape 1987-2000 F-B-Series 2000-2007 F-650, F-750 LINCOLN: 1980-1997 Town Car 1981-1997 Continental 1993-1997 Mark VIII 1998-2004 Navigator 2002-2003 Blackwood MERCURY: 1980-1997 Grand Marquis 1981-1997 Cougar 1986-1997 Sable 1987-1999 Tracer 1995-2000 Mystique 1999-2002 Cougar 1993-2002 Villager 1997 Mountaineer 2005-2007 Mariner MERKUR: 1985-1989 XR4TI This article supersedes TSB 01-15-7 to update the vehicle application chart. ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid. ACTION Beginning immediately all automatic transmission / transaxle applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will only continue for however long it takes to deplete what remains in inventory. SERVICE PROCEDURE Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 06-14-4 > Jul > 06 > A/T - Mercon V ATF Usage > Page 504 Service automatic transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V For proper fluid application on current and past model vehicles equipped with automatic transmissions I transaxles refer to the fluid usage chart. (Figure 1) CAUTION AUTOMATIC TRANSMISSIONS / TRANSAXLES THAT REQUIRE MERCON® V SHOULD STILL ONLY USE MERCON(R) V OR DUAL USAGE FLUID LABELED MERCON(R) / MERCON(R) V. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 06-14-4 > Jul > 06 > A/T - Mercon V ATF Usage > Page 505 CAUTION MERCON(R) SP, MOTORCRAFT PREMIUM AUTOMATIC TRANSMISSION FLUID AND MOTORCRAFT M5 ATFS ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS RECOMMENDING THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR TRANSMISSION DAMAGE. CAUTION THE FUNCTIONAL CHARACTERISTICS OF FLUIDS FOR CVT TRANSMISSIONS ARE VERY DIFFERENT THAN THOSE OF OTHER AUTOMATIC TRANSMISSION FLUIDS (ATFS). USE OF A FLUID OTHER THAN MOTORCRAFT CONTINUOUSLY VARIABLE CHAIN TYPE TRANSMISSION FLUID OR ONE LABELED AS MEETING MERCON(R) C WILL CAUSE FUNCTIONALITY CONCERNS AND INTERNAL TRANSMISSION DAMAGE. CAUTION DO NOT USE AUTOMATIC TRANSMISSION FLUID SUPPLEMENTS, ADDITIVES, TREATMENTS OR CLEANING AGENTS. Parts Block WARRANTY STATUS: Information Only Disclaimer Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 871814 > Sep > 87 > A/T, M/T - New `Mercon' Transmission Fluid Fluid - A/T: All Technical Service Bulletins A/T, M/T - New `Mercon' Transmission Fluid TRANSMISSION - AUTOMATIC/MANUAL - Article No. NEW FLUID AND USAGE CHART 87-18-14 FORD: 1986 And Prior LTD 1988 And Prior ESCORT, TEMPO, MUSTANG, TAURUS, THUNDERBIRD, FORD LINCOLN-MERCURY: 1986 And Prior CAPRI, MARQUIS 1987 And Prior LYNX 1988 And Prior TOPAZ, SABLE, COUGAR, MERCURY, MARK VII, CONTINENTAL, LINCOLN TOWN CAR MERKUR: 1985-88 XR4Ti 1988 SCORPIO LIGHT TRUCK: 1988 And Prior E SERIES, F SERIES, BRONCO, RANGER, BRONCO II, AEROSTAR ISSUE: A new Transmission Fluid, MERCON (Ford Specification "MERCON") (XT-2- QDX, Quart), (XT-2-DDX, 55 Gallon Drum) is available for service. Use of the Motorcraft "MERCON" transmission fluid, where specified, will improve cold weather shift effort and synchronized operation. ACTION: The chart on page 44 of this TSB gives transmission fluid applications for automatic transmissions and certain manual transmissions for Ford, Lincoln-Mercury, and Merkur vehicles. NOTE: The use of MERCON is NOT RECOMMENDED for power steering systems. The manual transmission lubricant for the 1985 Merkur XR4Ti is a semi-synthetic oil. When adding oil to the transmission, use only E5RY-19C547-A (Ford Specification ESD-M2C175-A) or equivalent. PART NUMBER PART NAME CLASS XT-2-QDX MERCON - Quart V Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 871814 > Sep > 87 > A/T, M/T - New `Mercon' Transmission Fluid > Page 510 XT-2-DDX MERCON - 55 Gallon V Drum E5RY-19C547-A Semi-Synthetic Oil B OTHER APPLICABLE ARTICLES: 82-9-9 Supersedes 85-1-15, 85-6-7 WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 861117 > Jun > 86 > A/T - Synthetic Fluid Availability Fluid - A/T: All Technical Service Bulletins A/T - Synthetic Fluid Availability Article No. 86-11-17 TRANSMISSION - AUTOMATIC - NEW SYNTHETIC DEXRON II ALL WEATHER AUTOMATIC TRANSMISSION FLUID FORD 1986 and PRIOR ESCORT, EXP, FORD, LTD, THUNDERBIRD, MUSTANG, TEMPO; 1986 TAURUS LINCOLN-MERCURY 1982-83 LN7; 1986 and PRIOR LYNX, MERCURY, MARQUIS, COUGAR, CAPRI, TOPAZ, LINCOLN, MARK, CONTINENTAL; 1986 SABLE LIGHT TRUCK 1986 and PRIOR E, F SERIES, BRONCO, BRONCO II, RANGER A new synthetic Dexron II automatic transmission fluid specification number ESR-M2C163-A2, part number E6AZ-19582-B is now available. This fluid will maintain a more constant viscosity through a wider range of temperatures. In the event a vehicle will be operated in extremely cold temperatures for an extended period of time, remove all existing fluid from the transmission (using the procedure shown in the applicable 1986 Car or Light Truck Shop Manual) and replace with the new synthetic Dexron II fluid, E6AZ-19582-B. The synthetic fluid is year 'round fluid and will not require replacement for warmer weather. CAUTION: DO NOT use synthetic Dexron II fluid in transmissions designed to use Type "F" fluid. PART NUMBER PART NAME CLASS E6AZ-19582-B Synthetic Dexron Oil V Automatic Transmission Oil OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 06-14-4 > Jul > 06 > A/T - Mercon V ATF Usage Fluid - A/T: All Technical Service Bulletins A/T - Mercon V ATF Usage TSB 06-14-4 07/24/06 MERCON ATF IS BEING REPLACED BY MERCON V ATF AS A SERVICE FLUID. FORD: 1980-1997 Crown Victoria 1981-1997 Mustang, Thunderbird 1981-2003 Escort 1986-1993 Festiva 1986-1997 Taurus 1989-1997 Probe 1994-1997 Aspire 1995-2000 Contour 1980-1996 Bronco 1981-2003 F-150 1981-2004 E-Series, F-Super Duty 1983-1996 Ranger 1986-1996 Aerostar 1991-1997 Explorer 1993-2004 F-53 Motorhome Chassis 1995-1998 Windstar 1997-2004 Expedition 2000-2005 Excursion 2001-2007 Escape 1987-2000 F-B-Series 2000-2007 F-650, F-750 LINCOLN: 1980-1997 Town Car 1981-1997 Continental 1993-1997 Mark VIII 1998-2004 Navigator 2002-2003 Blackwood MERCURY: 1980-1997 Grand Marquis 1981-1997 Cougar 1986-1997 Sable 1987-1999 Tracer 1995-2000 Mystique 1999-2002 Cougar 1993-2002 Villager 1997 Mountaineer 2005-2007 Mariner MERKUR: 1985-1989 XR4TI This article supersedes TSB 01-15-7 to update the vehicle application chart. ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid. ACTION Beginning immediately all automatic transmission / transaxle applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will only continue for however long it takes to deplete what remains in inventory. SERVICE PROCEDURE Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 06-14-4 > Jul > 06 > A/T - Mercon V ATF Usage > Page 520 Service automatic transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V For proper fluid application on current and past model vehicles equipped with automatic transmissions I transaxles refer to the fluid usage chart. (Figure 1) CAUTION AUTOMATIC TRANSMISSIONS / TRANSAXLES THAT REQUIRE MERCON® V SHOULD STILL ONLY USE MERCON(R) V OR DUAL USAGE FLUID LABELED MERCON(R) / MERCON(R) V. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 06-14-4 > Jul > 06 > A/T - Mercon V ATF Usage > Page 521 CAUTION MERCON(R) SP, MOTORCRAFT PREMIUM AUTOMATIC TRANSMISSION FLUID AND MOTORCRAFT M5 ATFS ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS RECOMMENDING THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR TRANSMISSION DAMAGE. CAUTION THE FUNCTIONAL CHARACTERISTICS OF FLUIDS FOR CVT TRANSMISSIONS ARE VERY DIFFERENT THAN THOSE OF OTHER AUTOMATIC TRANSMISSION FLUIDS (ATFS). USE OF A FLUID OTHER THAN MOTORCRAFT CONTINUOUSLY VARIABLE CHAIN TYPE TRANSMISSION FLUID OR ONE LABELED AS MEETING MERCON(R) C WILL CAUSE FUNCTIONALITY CONCERNS AND INTERNAL TRANSMISSION DAMAGE. CAUTION DO NOT USE AUTOMATIC TRANSMISSION FLUID SUPPLEMENTS, ADDITIVES, TREATMENTS OR CLEANING AGENTS. Parts Block WARRANTY STATUS: Information Only Disclaimer Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 871814 > Sep > 87 > A/T, M/T - New `Mercon' Transmission Fluid Fluid - A/T: All Technical Service Bulletins A/T, M/T - New `Mercon' Transmission Fluid TRANSMISSION - AUTOMATIC/MANUAL - Article No. NEW FLUID AND USAGE CHART 87-18-14 FORD: 1986 And Prior LTD 1988 And Prior ESCORT, TEMPO, MUSTANG, TAURUS, THUNDERBIRD, FORD LINCOLN-MERCURY: 1986 And Prior CAPRI, MARQUIS 1987 And Prior LYNX 1988 And Prior TOPAZ, SABLE, COUGAR, MERCURY, MARK VII, CONTINENTAL, LINCOLN TOWN CAR MERKUR: 1985-88 XR4Ti 1988 SCORPIO LIGHT TRUCK: 1988 And Prior E SERIES, F SERIES, BRONCO, RANGER, BRONCO II, AEROSTAR ISSUE: A new Transmission Fluid, MERCON (Ford Specification "MERCON") (XT-2- QDX, Quart), (XT-2-DDX, 55 Gallon Drum) is available for service. Use of the Motorcraft "MERCON" transmission fluid, where specified, will improve cold weather shift effort and synchronized operation. ACTION: The chart on page 44 of this TSB gives transmission fluid applications for automatic transmissions and certain manual transmissions for Ford, Lincoln-Mercury, and Merkur vehicles. NOTE: The use of MERCON is NOT RECOMMENDED for power steering systems. The manual transmission lubricant for the 1985 Merkur XR4Ti is a semi-synthetic oil. When adding oil to the transmission, use only E5RY-19C547-A (Ford Specification ESD-M2C175-A) or equivalent. PART NUMBER PART NAME CLASS XT-2-QDX MERCON - Quart V Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 871814 > Sep > 87 > A/T, M/T - New `Mercon' Transmission Fluid > Page 526 XT-2-DDX MERCON - 55 Gallon V Drum E5RY-19C547-A Semi-Synthetic Oil B OTHER APPLICABLE ARTICLES: 82-9-9 Supersedes 85-1-15, 85-6-7 WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Refill Capacity Fluid - A/T: Specifications Type MERCON(R) Automatic Transmission Fluid CAPACITY, Initial Refill*: C-6 5.0 qt (US) With the engine at operating temperature, shift transmission through all gears. Check fluid level in PARK and add fluid as needed Others 3.0 qt (US) Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Refill Capacity > Page 529 Fluid - A/T: Specifications Type MA(MERCON (R) Automatic Transmission Fluid) CAPACITY, Total Fill: Tempo, Topaz 8.3 qt (US) Others 9.8 qt (US) Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Drivetrain - Lubricant Usage Fluid - M/T: Technical Service Bulletins Drivetrain - Lubricant Usage Article No. 89-8-16 ^ DRIVETRAIN - LUBRICATION USAGE ^ TRANSMISSION - MANUAL - LUBRICATION USAGE LIGHT TRUCK: 1980-89 BRONCO, ECONOLINE, F-150, F-250, F-350 1983-89 RANGER 1984-89 BRONCO II 1986-89 AEROSTAR ISSUE: A quick reference manual transmission fluid usage chart and a quick reference drivetrain lubrication usage chart for light trucks has been put together to assist technicians in the event service is required. FIGURE 1 FIGURE 2 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Drivetrain - Lubricant Usage > Page 534 ACTION: Refer to the transmission fluid application chart in Figure 1 for the correct fluid usage. Refer to the drivetrain lubrication application chart in Figure 2 for the correct lubricant usage. PART NUMBER PART NAME CLASS D8DZ-19C547-A Standard Transmission BG Lubricant - 5 gallons C1AZ-19590-BA Long Life Lubricant B (molybdenum disulfide) - 14.5 ounces DOAZ-19584-AA Multi-Purpose Grease - 4 ounce B tube D7AZ-19584-AA Multi-Purpose Grease - 15 B ounce aerosol can XT-2-QDX Transmission Fluid (Mercon) - V quart can (pkg. of 12) C6AZ-19580-E Gear Oil (Dana axle) - 1 gallon AG C8AZ-19B546-A Additive Friction Modifier - 4 AM ounce bottle D7AZ-19590-A Disc Brake Caliper Slide AM Grease - 4 ounce tube E8TZ-19590-A Grease - 14.5 ounces B E1TZ-19590-A Automatic Hublock Grease - 5 B ounce tube E5RY-19C547-A Merkur Synthetic Manual B Transmission Fluid OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 5970 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Drivetrain - Lubricant Usage > Page 535 Fluid - M/T: Technical Service Bulletins A/T, M/T - New `Mercon' Transmission Fluid TRANSMISSION - AUTOMATIC/MANUAL - Article No. NEW FLUID AND USAGE CHART 87-18-14 FORD: 1986 And Prior LTD 1988 And Prior ESCORT, TEMPO, MUSTANG, TAURUS, THUNDERBIRD, FORD LINCOLN-MERCURY: 1986 And Prior CAPRI, MARQUIS 1987 And Prior LYNX 1988 And Prior TOPAZ, SABLE, COUGAR, MERCURY, MARK VII, CONTINENTAL, LINCOLN TOWN CAR MERKUR: 1985-88 XR4Ti 1988 SCORPIO LIGHT TRUCK: 1988 And Prior E SERIES, F SERIES, BRONCO, RANGER, BRONCO II, AEROSTAR ISSUE: A new Transmission Fluid, MERCON (Ford Specification "MERCON") (XT-2- QDX, Quart), (XT-2-DDX, 55 Gallon Drum) is available for service. Use of the Motorcraft "MERCON" transmission fluid, where specified, will improve cold weather shift effort and synchronized operation. ACTION: The chart on page 44 of this TSB gives transmission fluid applications for automatic transmissions and certain manual transmissions for Ford, Lincoln-Mercury, and Merkur vehicles. NOTE: The use of MERCON is NOT RECOMMENDED for power steering systems. The manual transmission lubricant for the 1985 Merkur XR4Ti is a semi-synthetic oil. When adding oil to the transmission, use only E5RY-19C547-A (Ford Specification ESD-M2C175-A) or equivalent. PART NUMBER PART NAME CLASS XT-2-QDX MERCON - Quart V Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Drivetrain - Lubricant Usage > Page 536 XT-2-DDX MERCON - 55 Gallon V Drum E5RY-19C547-A Semi-Synthetic Oil B OTHER APPLICABLE ARTICLES: 82-9-9 Supersedes 85-1-15, 85-6-7 WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Page 537 Fluid - M/T: Specifications TYPE 80W EP CAPACITY, Refill: 3-speed 3.5 pt (US) 4-speed ex. OD 7.0 pt (US) W/OD 4.5 pt (US) Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Drivetrain - Lubricant Usage Fluid - Differential: Technical Service Bulletins Drivetrain - Lubricant Usage Article No. 89-8-16 ^ DRIVETRAIN - LUBRICATION USAGE ^ TRANSMISSION - MANUAL - LUBRICATION USAGE LIGHT TRUCK: 1980-89 BRONCO, ECONOLINE, F-150, F-250, F-350 1983-89 RANGER 1984-89 BRONCO II 1986-89 AEROSTAR ISSUE: A quick reference manual transmission fluid usage chart and a quick reference drivetrain lubrication usage chart for light trucks has been put together to assist technicians in the event service is required. FIGURE 1 FIGURE 2 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Drivetrain - Lubricant Usage > Page 542 ACTION: Refer to the transmission fluid application chart in Figure 1 for the correct fluid usage. Refer to the drivetrain lubrication application chart in Figure 2 for the correct lubricant usage. PART NUMBER PART NAME CLASS D8DZ-19C547-A Standard Transmission BG Lubricant - 5 gallons C1AZ-19590-BA Long Life Lubricant B (molybdenum disulfide) - 14.5 ounces DOAZ-19584-AA Multi-Purpose Grease - 4 ounce B tube D7AZ-19584-AA Multi-Purpose Grease - 15 B ounce aerosol can XT-2-QDX Transmission Fluid (Mercon) - V quart can (pkg. of 12) C6AZ-19580-E Gear Oil (Dana axle) - 1 gallon AG C8AZ-19B546-A Additive Friction Modifier - 4 AM ounce bottle D7AZ-19590-A Disc Brake Caliper Slide AM Grease - 4 ounce tube E8TZ-19590-A Grease - 14.5 ounces B E1TZ-19590-A Automatic Hublock Grease - 5 B ounce tube E5RY-19C547-A Merkur Synthetic Manual B Transmission Fluid OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 5970 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Drivetrain - Lubricant Usage > Page 543 Fluid - Differential: Technical Service Bulletins Front/Rear Drive Axles - Lubricant Drain/Fill Procedure Article No. 83-3-23 FRONT AND REAR DRIVE AXLES - LUBRICANT DRAIN AND FILL PROCEDURE LIGHT TRUCKS 1979-83 F100-350, BRONCO, E100-350, RANGER, BRONCO II The following is the recommended procedure for draining axle lubricant from front and/or rear driving axles on all light truck models. 1. Drive the vehicle for 10-15 miles at highway speed to warm axle lubricant to operating temperature and minimum viscosity. 2. Raise the vehicle on a hoist and place a drain pan under the axle to be drained. 3. Wire brush the filler plug area of the axle housing cover or carrier assembly to prevent possible entry of dirt, rust, etc. into the axle assembly. 4. Remove the axle lubricant fill plug. 5. Using a suitable suction-type utility pump (manual or powered), drain the axle lubricant from the axle by inserting the pump suction hose through axle filler plug hole down into the lowest portion of the axle carrier housing removing all the lubricant. 6. Fill the axle housing with the specified amount and type of lubricant as shown on the following specification charts. 7. Install the filler plug and torque as shown on the following specification charts. FRONT/REAR DRIVING AXLE SPECIFICATION CHARTS I. Filler Rug Torque Chart Axle Fill Plug Torque All Dana Front/Rear 20-30 Ft.Lbs. - Ford Built Rear Axles 25-50 Ft.Lbs. II. Axle Lubricant Capacities - Econoline Approximate Capacity (1) U.S. Pints (2) Ford Standard and Traction-Lok 5.5 (3) (E-100/150) Dana Standard and Limited Slip 6.0 (4) (E-250, Model 60/61-2) Dana Standard and Limited Slip 6.5 (4) (Model 70), Dual Rear Wheels Ford Standard and Traction-Lok 5.5 (E-250 Van) Dana Standard and Limited Slip 6.0 (4) (Model 61-1) Single Rear Wheels (1) Service refill capacities are determined by filling to the bottom of the filler hole. (2) All Ford Conventional and Traction-Lok Rear Axles Use ESP-M2C154-A All Dana Conventional and Limited-Slip Rear Axles - Use ESW-M2C105-A (3) Add 4 ounces of EST-M2C118-A (Friction Modifier C8AZ-19B546-A) for complete fill of Ford TractionLok axle. (4) Add 4 ounces of EST-M2C118-A (Friction Modifier C8AZ-19B546-A) for complete refill of Dana Rear Limited-Slip Axle. III. Axle Lubricant Capacities - Bronco Chart Approximate Capacity (1) U.S. Pints Front Axle (5) Dana 3.8 (3) Rear Axle (4) Ford 5.5 (2) (1) Refill Capacity is determined by filling to the bottom of the filler hole. (2) All Ford Conventional and Traction-Lok Rear Axles Use ESP-M2C154-A. (3) All Dana Conventional and Limited-Slip Front Drive Axles - Use ESW-M2C105-A. (4) Add 4 ounces of EST-M2C118-A (Friction Modifier C8AZ-19B546-A) for complete fill of Ford TractionLok Axle (1979-1982). Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Technical Service Bulletins > Drivetrain - Lubricant Usage > Page 544 (5) Add 2 ounces of EST-M2C118-A (Friction Modifier C8AZ-19B546-A) for complete refill of Dana Front Limited-Slip Axle. IV. Axle Lubricant Capacities - F100 - F350 (4x2/4x4) Approximate Capacity (1) U.S. Measure Axle Model (4) Truck Type (Pints) Ford 8.8" and 9" F100/150/250 5.5 (3) Dana 44-IFS (Front Axle) F150/250 (4x4) 3.8 Dana 60 (Rear) F250 6.0 Dana 61-2 (Rear) F250 6.0 Dana 50-IFS (Front Axle) F250/350 (4x4) Heavy 4.1 Duty & Snow Plow Dana 70 (Rear) F350 DRW Chassis Cab 6.5 Dana 70 HD (Rear) F350 DRW Regular Cab 7.4 Dana 61-1 (Rear F250/350 SRW 6.0 (1) Service refill capacities are determined by filling to the bottom of the filler hole. (2) Add EST-M2C118-A (Friction Modifier Part No. C8AZ-19B546-A) for complete refill of Dana LimitedSlip axles. Add 4 ounces for F250/350 Rear. For F150 & F250 4x4 add 2 ounces to front axle. (3) Add 4 ounces of EST-M2C118-A (Friction Modifier C8AZ-19B546-A) for complete fill of Ford TractionLok Axle (1979-1982). (4) All Ford Conventional and Traction-Lok Rear Axles Use ESP-M2C154-A. All Dana Conventional and Limited-Slip Front/Rear Axles - Use ESW-M2C105-A. V. Axle Lubricant Capacities - Ranger 4x2/4x4, Bronco II Approximate Capacities U.S. Imperial Measure Measure (Pints) (Pints) Liters Rear Ford 6-3/4 Ring Gear (1)(4) 3.0 2.5 1.4 Rear Ford 7.5 Ring Gear (2)(4) 5.0 (6) 4.2 2.4 Dana 28 Front Axle (4x4 Only)(3)(5) 1.0 (7) 0.83 0.45 Bronco II Ford 7.5 Ring Gear(2)(4) 5.5 (6) 4.6 2.6 (1) Fill to 3/8 in. +/- 1/8 in. (9.5 mm +/- 3 mm) below bottom of fill hole. Base GVW axle with 2.0L engine and 2.3L engine with automatic. (2) Fill to 1/2 in. +/- 1/8 in. (12.7 mm t 3 mm) below bottom of fill hole. Optional GVW or 2.3L engine. (3) Fill to 1/2 in. +/- 1/8 in. (12.7 mm + 3 mm) below bottom of fill hole. (4) All Ford Conventional and Traction-Lok Rear Axles Use ESP-M2C154-A. (5) All Dana Conventional and Limited-Slip Front Axles - Use ESW-M2C105-A. (6) Add 4 ounces of EST-M2C118-A (Friction Modifier C8AZ-19B546-A) for complete fill of Ford TractionLok Axle. (7) Add 1/2 ounce of EST-M2C118-A (Friction Modifier C8AZ-19B546-A) for complete refill of Dana Front Limited-Slip Axle. PART NUMBER PART NAME CLASS E0AZ-19580-A Lubricant-ESP-M2C154-A AM C6AZ-19580-E Lubricant-ESW-M2C105-A AG C8AZ-19B546-A Friction Modifier-EST-M2C118-A A OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications TYPE: Standard 90 HP Limited-Slip 90 HP* CAPACITY, Refill: Front: All models 4.0 pt (US) LIMITED-SLIP OR TRACTION-LOK IDENTIFICATION: Letter & number on plate on door lock pillar Rear: Dana 60 5.0 pt (US) Dana 61 6.0 pt (US) 1982 70 HD 7.4 pt (US) 1981 Econoline w/Dana 70 7.0 pt (US) Others 6.5 pt (US) Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 547 Fluid - Differential: Fluid Type Specifications BL Self-adjusting Brake Lubricant EC Ethylene Glycol Coolant Mix 50/50 with water to at least -20°F (-29°C) protection EP Extreme Pressure Gear Lubricant Ford Part No. D8DZ-19C547-A FA Automatic Transmission Fluid, Type F GL-5 Gear Oil, API Service GL-5 HBH Hydraulic Brake Fluid, Extra Heavy-Duty HP Hypoid Gear Oil Ford Part No. E0AZ-19580-A HP* Hypoid Gear Oil for Limited-Slip or Traction-Lok Differential LM Lithium Grease, with Polyethylene LS Steering Gear Lubricant MA MERCONAutomatic Transmission Fluid MH Manifold Heat Valve Solvent SG Motor Oil, API Service SG Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Lubricant Usage Fluid - Transfer Case: Technical Service Bulletins Drivetrain - Lubricant Usage Article No. 89-8-16 ^ DRIVETRAIN - LUBRICATION USAGE ^ TRANSMISSION - MANUAL - LUBRICATION USAGE LIGHT TRUCK: 1980-89 BRONCO, ECONOLINE, F-150, F-250, F-350 1983-89 RANGER 1984-89 BRONCO II 1986-89 AEROSTAR ISSUE: A quick reference manual transmission fluid usage chart and a quick reference drivetrain lubrication usage chart for light trucks has been put together to assist technicians in the event service is required. FIGURE 1 FIGURE 2 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Lubricant Usage > Page 552 ACTION: Refer to the transmission fluid application chart in Figure 1 for the correct fluid usage. Refer to the drivetrain lubrication application chart in Figure 2 for the correct lubricant usage. PART NUMBER PART NAME CLASS D8DZ-19C547-A Standard Transmission BG Lubricant - 5 gallons C1AZ-19590-BA Long Life Lubricant B (molybdenum disulfide) - 14.5 ounces DOAZ-19584-AA Multi-Purpose Grease - 4 ounce B tube D7AZ-19584-AA Multi-Purpose Grease - 15 B ounce aerosol can XT-2-QDX Transmission Fluid (Mercon) - V quart can (pkg. of 12) C6AZ-19580-E Gear Oil (Dana axle) - 1 gallon AG C8AZ-19B546-A Additive Friction Modifier - 4 AM ounce bottle D7AZ-19590-A Disc Brake Caliper Slide AM Grease - 4 ounce tube E8TZ-19590-A Grease - 14.5 ounces B E1TZ-19590-A Automatic Hublock Grease - 5 B ounce tube E5RY-19C547-A Merkur Synthetic Manual B Transmission Fluid OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 5970 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications TYPE MERCON(R) Automatic Transmission Fluid CAPACITY, Refill: NP208 7.0 pt (US) Warner 1345 6.5 pt (US) Warner 1350 Ranger 3.0 pt (US) Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 555 Fluid - Transfer Case: Fluid Type Specifications BL Self-adjusting Brake Lubricant EC Ethylene Glycol Coolant Mix 50/50 with water to at least -20°F (-29°C) protection EP Extreme Pressure Gear Lubricant Ford Part No. D8DZ-19C547-A FA Automatic Transmission Fluid, Type F GL-5 Gear Oil, API Service GL-5 HBH Hydraulic Brake Fluid, Extra Heavy-Duty HP Hypoid Gear Oil Ford Part No. E0AZ-19580-A HP* Hypoid Gear Oil for Limited-Slip or Traction-Lok Differential LM Lithium Grease, with Polyethylene LS Steering Gear Lubricant MA MERCONAutomatic Transmission Fluid MH Manifold Heat Valve Solvent SG Motor Oil, API Service SG Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - Oil Level Checking Procedure Engine Oil: Technical Service Bulletins Engine - Oil Level Checking Procedure Article No. 85-25-20 OIL DIPSTICK - ENGINE OIL LEVEL CHECKING PROCEDURE - GASOLINE ENGINES LIGHT TRUCK 1986 AND PRIOR MEDIUM/HEAVY TRUCK 1986 AND PRIOR Figure 17 - Dipstick To correctly check the engine oil level, the vehicle must be parked on a level surface. Allow a few minutes after shutting the engine off for oil to drain down before checking. For consistent oil level readings, insert the dipstick with the loop of the handle as shown in Figure 17. Figure 18 - Dipstick - Calibration Figure 19 - Dipstick - Calibration Dipsticks in Ford vehicles do not incorporate a Full mark. Instead, the dipstick will have marks indicating a Safe range and an Add range as shown in Figure 18 or 19. When the correct amount of oil is in the engine, the oil level indication will be in the Safe range or above the Minimum mark, but not necessarily at the top of the Safe range or at the Maximum mark. When the indicated oil level is in the Add range put one quart of oil in the engine. Recheck the oil level to determine if the oil level is now in the Safe range or above the Minimum mark. Add and recheck oil level one quart at a time until the oil level indicator moves into the Safe range or above the Minimum mark. Do not add additional oil to bring the level to the top of the Safe range or to the Maximum mark since this may result in overfill and increased oil consumption. If the accuracy of the engine oil dipstick is in doubt, it may be verified in the following manner: ^ Drain the oil and install a new filter. ^ Put in the specified amount of oil for an oil and filter change. (See owner guide) ^ Start the engine and operate a few minutes. ^ Shut off the engine and allow a few minutes for the oil to drain down. ^ Check the oil level with the dipstick. ^ If the oil level does not indicate in the Safe range or above the Minimum mark, rework or replace the dipstick. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine oil capacity ............................................................................................................................... ........................................................... 5.0 Qts.(4.7L) Note: Add 1 Qt. with filter change. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 562 Engine Oil: Fluid Type Specifications BL Self-adjusting Brake Lubricant EC Ethylene Glycol Coolant Mix 50/50 with water to at least -20°F (-29°C) protection EP Extreme Pressure Gear Lubricant Ford Part No. D8DZ-19C547-A FA Automatic Transmission Fluid, Type F GL-5 Gear Oil, API Service GL-5 HBH Hydraulic Brake Fluid, Extra Heavy-Duty HP Hypoid Gear Oil Ford Part No. E0AZ-19580-A HP* Hypoid Gear Oil for Limited-Slip or Traction-Lok Differential LM Lithium Grease, with Polyethylene LS Steering Gear Lubricant MA MERCONAutomatic Transmission Fluid MH Manifold Heat Valve Solvent SG Motor Oil, API Service SG Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement Technical Service Bulletin # 98-12-5 Date: 980622 A/C - Filtering Refrigerant After Compressor Replacement Article No. 98-12-5 06/22/98 AIR CONDITIONING - FILTERING REFRIGERANT AFTER A/C COMPRESSOR REPLACEMENT - SERVICE TIPS FORD: 1980-98 CROWN VICTORIA 1981-98 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-97 THUNDERBIRD 1982-98 MUSTANG 1983-86 LTD 1984-94 TEMPO 1986-98 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-98 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1980-98 GRAND MARQUIS, TOWN CAR 1982-83 ZEPHYR 1982-86 CAPRI 1982-87 LN7 1982-97 COUGAR 1982-98 CONTINENTAL 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-98 SABLE 1991-94 CAPRI 1991-98 TRACER 1993-98 MARK VIII 1995-98-MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1980-96 BRONCO 1980-97 F SUPER DUTY 1980-98 ECONOLINE, F-150, F-150, F-350 1983-98 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F-47 1991-98 EXPLORER 1993-98 VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to revise the Service Procedure and to update the model years. ISSUE Vehicles that have and inoperative A/C compressor, due to internal causes, MUST have the refrigerant system cleaned to remove any debris or contaminants that may be present to prevent damage to the replacement compressor. ACTION Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 567 Install a Service Filter Kit in the refrigerant system prior to installing the replacement compressor. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-15-5 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-99 Models And 1991 Lincolns, Basic Warranty Coverage For All Other Models And Major Component Warranty Coverage For All Other Lincoins OPERATION DESCRIPTION TIME 981205A Kit Installation 1.2 Hrs. 981205B Extra Time For Refrigerant 0.4 Hr. (R-12) Recovery DEALER CODING CONDITION BASIC PART NO. CODE 19703 49 OASIS CODES: 208000, 208999 Service Procedure THIS PROCEDURE IS OPTIONAL IF THE SYSTEM IS FLUSHED USING THE ROTUNDA A/C FLUSHER. CAUTION THIS FILTERING PROCEDURE MAY BE USED FOR EITHER R-12 OR R-134a REFRIGERANT SYSTEMS. BECAUSE THE TWO (2) SYSTEMS USE DIFFERENT REFRIGERANT OILS AND BECAUSE THE COMPRESSOR COULD BE DAMAGED IF THE WRONG OIL IS USED, SYSTEM IDENTIFICATION IS VERY IMPORTANT. BE SURE SYSTEM IS CORRECTLY IDENTIFIED BEFORE STARTING THE FILTERING PROCEDURE. Each Service Filter Kit includes the following items: ^ One (1) Pancake Filter (to be installed in the liquid line between the condenser and the orifice tube) ^ One (1) Instruction Sheet NOTE ON 1993-94 RANGER/EXPLORER VEHICLES, TECHNICIANS MAY EXPERIENCE DIFFICULTY WHEN CONNECTING THE PANCAKE FILTER HOSE FITTINGS TO THE EVAPORATOR INLET WITH THE ORIFICE TUBE INSTALLED. REMOVE THE OFFICE TUBE AND RUN THE SYSTEM FOR 1 HOUR AS DESCRIBED IN THE FILTERING PROCEDURE. REINSTALL THE ORIFICE TUBE AFTER FILTERING IS COMPLETE. CAUTION FOLLOW ALL REFRIGERANT SYSTEM SAFETY AND SERVICE PRECAUTIONS OUTLINED IN THE APPROPRIATE SERVICE OR WORKSHOP MANUAL. 1. Before removing any refrigerant system components, recover the refrigerant from the system following the recycling methods outlined In the appropriate Service/Workshop Manual. 2. Remove the suction accumulator/drier assembly and drain the oil into a calibrated container. 3. Install a new suction accumulator/drier and add new refrigerant oil to replace the old oil. The quantity of the new oil to be added is the amount to match that drained from the old accumulator plus 60 mL (2 oz). Refer to the Dealer Master Parts Catalog for the correct suction accumulator/drier part number. CAUTION REMEMBER TO USE MOTORCRAFT YN-9-A REFRIGERANT COMPRESSOR OIL WITH R-12 SYSTEMS AND MOTORCRAFT YN-12-C REFRIGERANT COMPRESSOR OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. 4. Install a new orifice tube. Refer to the Dealer Master Parts Catalog for the correct orifice tube part number. If the orifice tube in the vehicle is located in the liquid line between the condenser and the evaporator, replace the liquid line assembly. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 568 5. Install pancake filter in the liquid line between the condenser and the orifice tube, Figure 1. a. Be sure orifice inlet is toward the condenser. b. Connections can be made using Test Adapter Set D93L-19703-B, or equivalent, and flexible refrigerant hose of 2500 psi burst rating. Individual fittings are also available. 6. Remove the old compressor following Service/Workshop Manual procedures. Drain the oil into a calibrated container. 7. Drain the oil from the replacement compressor into a clean calibrated container. NOTE: IT WILL BE NECESSARY TO TRANSFER THE MAGNET CLUTCH FROM THE OLD COMPRESSOR TO THE REPLACEMENT COMPRESSOR. FOLLOW SERVICE/WORKSHOP MANUAL PROCEDURES. 8. A new FX-15 service compressor contains 207 mL (7 oz.) of R-12 refrigerant oil. A new FS-10 service compressor does not contain any oil and can be used with an R-12 or an R-134a system. CAUTION REMEMBER TO USE YN-9-A (MINERAL) OIL WITH R-12 SYSTEMS AND YN-12-C (PAG) OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. ^ If the amount of oil drained from the removed compressor is between 90 and 148 mL (3-5 oz), pour the same amount of clean refrigerant oil into the new compressor. ^ If the amount of oil drained from the old compressor is greater than 90 mL (3 oz), pour 90 mL (3 oz) of clean refrigerant oil into the new compressor. 9. Install the new compressor following Service/Workshop Manual procedures. Make sure all mounting bolts are tightened properly. Check the tension of the compressor drive belt. Adjust if necessary. 10. Evacuate, charge and leak test the system, following Service/Workshop Manual procedures. 11. Check all refrigerant system hoses, lines and the position of the newly-installed filters to make sure they do not interfere with other engine compartment components. If necessary, use tie straps to make adjustments. 12. Set the A/C control on Max A/C, high blower and temperature control at full cold. a. Start engine and let idle briefly. b. Be sure A/C system is operating properly. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 569 13. Gradually bring the engine up to 1200 rpm by running it at lower rpms for short periods (first at 800 rpm, then at 1000 rpm). Set the engine at 1200 rpm and run it for an hour with the A/C system operating. 14. Stop the engine. NOTE: IT WILL BE NECESSARY TO RECOVER THE SYSTEM REFRIGERANT CHARGE BEFORE PROCEEDING. 15. Allow the engine to cool sufficiently to remove the fittings, flexible hoses and pancake filter from the liquid line. 16. Discard the filter. It can be used one (1) tie only. 17. Reconnect the liquid line back into the system. 18. Evacuate, charge and leak test the system. Make any necessary adjustments. 19. Check the operation of the system in all models. PART NUMBER PART NAME F8VZ-19E773-AA Filter Kit F73Z-19577-AA Refrigerant Oil - Motorcraft YN-9-A (For R-12 Refrigerant Systems Only) F7AZ-19589-DA Refrigerant Oil - Motorcraft YN-12-C (PAG-Type Oil For R-134a Refrigerant Systems Only) NOTE THE TOTAL REPAIR TIME IS FOR INSTALLING SERVICE FILTER KIT PER INSTRUCTIONS THIS INCLUDES INSTALLATION OF AND DISCARD OF FILTER. REFER TO SERVICE LABOR TIME STANDARDS MANUALS IF ADDITIONAL LABOR OPERATIONS ARE REQUIRED. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 570 Refrigerant: Technical Service Bulletins Air Conditioning - Use of Correct Fluorescent Tracer Dye Article No. 93-20-6 09/29/93 AIR CONDITIONING - USE OF CORRECT FLUORESCENT TRACER DYE - SERVICE TIP FORD: 1980-93 CROWN VICTORIA 1981-93 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-93 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-93 TEMPO 1986-93 TAURUS 1988-93 FESTIVA 1989-93 PROBE LINCOLN-MERCURY: 1980-93 GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1982-83 LN7, ZEPHYR 1982-86 CAPRI 1982-93 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-92 MARK VII 1984-93 TOPAZ 1986-93 SABLE 1991-93 CAPRI, TRACER LIGHT TRUCK: 1980-93 BRONCO, ECONOLINE, F-150-350 SERIES 1983-93 RANGER 1984-90 BRONCO II 1986-93 AEROSTAR 1988-93 F-47 1991-93 EXPLORER 1993 VILLAGER ISSUE: Use of untested, unapproved fluorescent tracer dyes for A/C system leak checking may damage the air conditioning system. Some of these materials may not be compatible with Ford A/C systems. ACTION: When leak-checking an R-12 A/C system with a "black light", use only Rotunda-supplied Part No. 112-R0027, Fluoro-Lite brand dye. No other dyes have been approved by Ford Motor Company. NOTE: 112-R0027 DYE IS NOT COMPATIBLE WITH R-134a REFRIGERANT. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208999 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 571 Refrigerant: Technical Service Bulletins R-12 Refrigerant - Substitutes Article No. 94-14-3 07/13/94 Air Conditioning - Use Of R-12 Refrigerant Substitutes - Service Tip FORD: 1980-93 CROWN VICTORIA 1981-93 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-93 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-93 TEMPO 1986-93 TAURUS 1988-93 FESTIVA 1989-93 PROBE LINCOLN-MERCURY: 1980-93 GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1982-83 LN7, ZEPHYR 1982-86 CAPRI 1982-93 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-92 MARK VII 1984-93 TOPAZ 1986-93 SABLE 1991-93 CAPRI, TRACER MERKUR: 1986-89 SCORPIO, XR4TI LIGHT TRUCK: 1980-93 BRONCO, ECONOLINE, F-150-350 SERIES 1983-93 RANGER 1984-90 BRONCO II 1986-93 AEROSTAR 1988-93 F-47 1991-93 EXPLORER 1992-94 F-53 1993 VILLAGER MEDIUM/HEAVY TRUCK: 1954-90 C SERIES 1970-94 L SERIES 1979-90 CL-9000, CL-CLT-9000 SERIES 1980-94 F SERIES 1986-94 CARGO SERIES This TSB is being republished in its entirety to include Heavy Truck models. ISSUE: A number of manufacturers are producing refrigerant products which are described as being direct replacements for refrigerant R-12. The use of any unauthorized substitute refrigerant may severely damage the A/C system components. ACTION: If service is required, use only NEW or RECYCLED refrigerant R-12. Ford Motor Company has not tested or approved any R-12 refrigerant substitute at this time. R-134a is approved only for systems which specify R-134a, Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 572 and is not compatible with R-12 systems. R-22 likewise, is not compatible with R-12 systems. CAUTION: USING ANY UNAUTHORIZED SUBSTITUTE REFRIGERANT FOR R-12 MAY RESULT IN SEVERE DAMAGE TO THE A/C SYSTEM COMPONENTS. OTHER APPLICABLE ARTICLES: 91-9-7 SUPERSEDES: 93-23-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208999, 290000 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 573 Refrigerant: Technical Service Bulletins A/C - R12 Refrigerant Substitutes Service Tip Article No. 96-17-10 08/12/96 AIR CONDITIONING - USE OF R-12 REFRIGERANT SUBSTITUTES - SERVICE TIP FORD: 1980-93 CROWN VICTORIA 1981-93 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-93 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-94 TEMPO 1986-93 TAURUS 1988-93 FESTIVA 1989-93 PROBE LINCOLN-MERCURY: 1980-93 GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1982-83 LN7, ZEPHYR 1982-86 CAPRI 1982-93 COUGAR 1982-94 CONTINENTAL 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-93 SABLE 1991-93 CAPRI, TRACER MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1980-93 BRONCO, ECONOLINE, F SUPER DUTY, F-150-350 SERIES 1983-93 RANGER 1984-90 BRONCO II 1986-93 AEROSTAR 1988-93 F-47 1991-93 EXPLORER 1993 VILLAGER MEDIUM/HEAVY TRUCK: 1985-94 CARGO SERIES, F & B SERIES, L SERIES This TSB article is being republished in its entirety to list Environmental Protection Agency (EPA) reviewed NC substitutes for R-12 refrigerant. ISSUE: A number of manufacturers are producing refrigerant products which are described as being direct replacements for refrigerant R-12. ACTION: If service is required, use only new or of known quality recycled refrigerant R-12. Ford Motor Company has approved R-134a as the only refrigerant substitute for R-12. CAUTION: USING ANY UNAUTHORIZED SUBSTITUTE REFRIGERANT FOR R-12 MAY RESULT IN SEVERE DAMAGE TO THE A/C SYSTEM COMPONENTS. INFORMATION FROM THE EPA Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 574 This information has been taken from EPA documents to address Ford specific applications and recommendations. Further EPA information on ozone-depleting substances and regulations regarding its handling can be found on the Internet at World Wide Web site: http://www.epa.gov/ozone/ In 1994, EPA established the Significant New Alternatives Policy (SNAP) program to review alternatives to ozone-depleting substances like R-12. EPA examines new substitutes for their ozone depleting, global warming, flammability, and toxicity characteristics. The SNAP process does not test these substitutes for A/C system compatibility, reliability, durability, or performance. Under the SNAP rule, each new refrigerant must be used in accordance with the following conditions: 1. Unique Fittings - Each new refrigerant must be used with a unique set of fittings to prevent the accidental mixing of different refrigerants. 2. Unique Equipment - Each refrigerant must have dedicated recovery/recycling equipment for that refrigerant. 3. Labels - Whether a vehicle is originally designed to use a new refrigerant or is retrofitted, the technician must apply a detailed label giving specific information about the alternative. This label covers up information about the old refrigerant and provides valuable details on the alternative and how it was used. The technician is required to fill in their name, company performing the retrofit, address and the date retrofitted. 4. Remove Original Refrigerant - The original R-12 must be removed from the system prior to charging with the new refrigerant. This will guarantee that the largest amount of clean R-12 is available for use in vehicles that still need it. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 575 A summary of the refrigerants reviewed under EPA's SNAP program for use in motor vehicle air conditioning systems is in the table. OTHER APPLICABLE ARTICLES: 91-9-7, 96-15-7 SUPERSEDES: 93-23-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208999, 290000 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Without Rear A/C ................................................................................................................................. ....................................................................... 3.5 lbs With Rear A/C ...................................................................................................................................... ..................................................................... 4.25 lbs Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 578 Refrigerant: Fluid Type Specifications Type ..................................................................................................................................................... ............................................... Refrigerant 12 (R-12) Ford Part Number ............................................. ........................................................................................................................................ D4AZ-19B519-A Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Refrigerant Oil System Capacity ......................................................................................................... ....................................................................... 10.5 oz Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 583 Refrigerant Oil: Fluid Type Specifications Compressor ................................................................................................................... 500 viscosity (C9AZ-19557-B or Motorcraft VN-2 or equivalent) Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair Brake Bleeding: Service and Repair Bleed primary and secondary hydraulic brake systems separately, bleeding longest line first on each system. Do not allow reservoir to run dry during bleeding operation. Never reuse fluid that has been drained from hydraulic system. 1. Loosen master cylinder to hydraulic line nuts and wrap shop cloths around tubing below fitting to absorb escaping brake fluid. 2. Depress brake pedal slowly by hand to floor of cab, forcing air trapped in master cylinder out at fitting. 3. Hold pedal down and tighten fittings, then release brake pedal. Releasing brake pedal before fittings are tightened will allow air to enter the master cylinder. 4. Repeat steps 1 through 3 until air ceases to escape at fittings and brake pedal is firm. 5. Bleed rear brakes as follows: a. Pump pedal several times, then hold pedal down firmly. b. With pedal firmly depressed, open bleeder screw on one rear brake until pedal fades to floor, then close bleeder valve. c. Repeat procedure until a continuous flow of brake fluid is released from bleeder valve. d. Repeat steps 5a through 5c on other rear brake. 6. Bleed front brakes using same procedure as for rear brakes. 7. Fill master cylinder reservoirs to {1/4} inch from top of reservoirs. 8. Centralize the pressure differential control valve, if applicable, as follows: a. Turn ignition switch to ``ACC'' or ``On'' position. b. Push brake pedal down, allowing piston to center itself, turning off warning light. c. Turn ignition switch to ``OFF'' position. 9. Check brake operation and ensure pedal is firm, then road test vehicle. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > Customer Interest for Fuse: > 851019 > May > 85 > A/C Blower Motor - Inoperative Fuse: Customer Interest A/C Blower Motor - Inoperative Article No. 85-10-19 AIR CONDITIONING - INOPERATIVE BLOWER MOTOR - DAMAGED FUSE OR FUSE HOLDER LIGHT TRUCK ALL 1985 AND PRIOR ECONOLINES When operating the A/C system for long periods of time with the blower motor set on high, the solder at the end of the A/C fuse melts with the additional loss of holder clip retention due to the heat build-up. A revised fuse holder is released to resolve the subject concern. The following procedure should be performed: 1. Check fuse for damage (solder melted at end of fuse). 2. Check fuse holder for proper retention of fuse (loss of fuse holder clip retention due to heat build-up). 3. If the fuse or fuse holder show no heat damage perform normal diagnostic procedures for inoperative A/C blower motor. If the fuse or fuse holder is found to be damaged as described in Steps 1 and 2 continue with Step 4. 4. Disconnect battery ground cable. 5. Remove two fuse panel retaining screws and turn fuse panel to expose back side of panel. 6. Locate the two orange wires (Circuit 181) leading to the A/C fuse holder. Cut both wires as close to the fuse panel as possible and remove the fuse holders from the fuse panel. 7. Install in-line fuse holder E5FZ-14517-A using 30 amp fuse D9ZZ-14526-G (green). Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > Customer Interest for Fuse: > 851019 > May > 85 > A/C Blower Motor - Inoperative > Page 596 Figure 23FUSE PANEL MOUNTED TO DASH PANEL LEFT OF STEERING COLUMN 8. Tape the fuse holder along the main wire harness as shown in Figure 23. 9. Re-install fuse panel, connect battery ground cable and check A/C system for proper operation. PART NUMBER PART NAME CLASS E5FZ-14517-A Fuse Holder R D9ZZ-14526-G Fuse A OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP14411A85 TIME: 0.4 Hr. DLR. CODING: Basic Part No. 14401 - Code: 28 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 851019 > May > 85 > A/C Blower Motor - Inoperative Fuse: All Technical Service Bulletins A/C Blower Motor - Inoperative Article No. 85-10-19 AIR CONDITIONING - INOPERATIVE BLOWER MOTOR - DAMAGED FUSE OR FUSE HOLDER LIGHT TRUCK ALL 1985 AND PRIOR ECONOLINES When operating the A/C system for long periods of time with the blower motor set on high, the solder at the end of the A/C fuse melts with the additional loss of holder clip retention due to the heat build-up. A revised fuse holder is released to resolve the subject concern. The following procedure should be performed: 1. Check fuse for damage (solder melted at end of fuse). 2. Check fuse holder for proper retention of fuse (loss of fuse holder clip retention due to heat build-up). 3. If the fuse or fuse holder show no heat damage perform normal diagnostic procedures for inoperative A/C blower motor. If the fuse or fuse holder is found to be damaged as described in Steps 1 and 2 continue with Step 4. 4. Disconnect battery ground cable. 5. Remove two fuse panel retaining screws and turn fuse panel to expose back side of panel. 6. Locate the two orange wires (Circuit 181) leading to the A/C fuse holder. Cut both wires as close to the fuse panel as possible and remove the fuse holders from the fuse panel. 7. Install in-line fuse holder E5FZ-14517-A using 30 amp fuse D9ZZ-14526-G (green). Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 851019 > May > 85 > A/C Blower Motor - Inoperative > Page 602 Figure 23FUSE PANEL MOUNTED TO DASH PANEL LEFT OF STEERING COLUMN 8. Tape the fuse holder along the main wire harness as shown in Figure 23. 9. Re-install fuse panel, connect battery ground cable and check A/C system for proper operation. PART NUMBER PART NAME CLASS E5FZ-14517-A Fuse Holder R D9ZZ-14526-G Fuse A OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP14411A85 TIME: 0.4 Hr. DLR. CODING: Basic Part No. 14401 - Code: 28 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > Page 603 Fuse: Locations LH Shroud, Near Access Hole Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Fuse Link B Fusible Link: Locations Fuse Link B Attached To Auxiliary Battery Relay Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Fuse Link B > Page 608 Fusible Link: Locations Fuse Link C Attached To Junction Block Or Auxiliary Battery Relay Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Fuse Link B > Page 609 Fusible Link: Locations Fuse Link D Attached To Junction Block Or Auxiliary Battery Relay Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Fuse Link B > Page 610 Fusible Link: Locations Fuse Link E At Starter Relay Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Fuse Link B > Page 611 Fusible Link: Locations Fuse Link B Attached To Auxiliary Battery Relay Fuse Link C Attached To Junction Block Or Auxiliary Battery Relay Fuse Link D Attached To Junction Block Or Auxiliary Battery Relay Fuse Link E At Starter Relay Fuse Link G At Starter Relay Fuse Link K At Junction Block Fuse Link L Connected To Junction Block Or Auxiliary Battery Relay Fuse Link M At Starter Relay Fuse Links A, G & H Attached To Starter Motor Relay Fuse Links G & H ( W/Ammeter) In Harness, RH Side Of Dash Panel Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > System Information > Service Precautions Service Reminder Indicators: Service Precautions SERVICE PRECAUTION All Service Reminder Indicators should be investigated or serviced immediately. Vehicle damage may result if the indicator is ignored. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 851916 > Sep > 85 > Tires - Front Outside Edge Wear Tires: Customer Interest Tires - Front Outside Edge Wear Article No. 85-19-16 TIRE WEAR - FRONT - OUTSIDE EDGE LIGHT TRUCK 1976-86 E100-150 Outboard shoulder wear, predominantly in lightly loaded city-delivery type use, is aggravated by excessive positive wheel camber in turning. The caster adjustment kit described in TSB 85-19-15 can be used to increase caster of either wheel up to 3 degrees in 1/2 degree increments. The kit contains complete instructions for modifying the front radius arms and mounting a metal adjusting cam to the bottom flange of each radius arm. Cams must be arc-welded a minimum of one inch along two sides of the cam to the lower flange of the radius arm. Increasing caster the full 3 degrees effectively reduces camber of the outboard wheel in a turn 1.5 degrees. Increasing caster more than 3 degrees is not recommended since this may cause complaints of wheel shimmy and/or excessive steering efforts. Also, caster should not be increased on vehicles built since April 1, 1984. These vehicles have the 3 degree caster increase already built into the axles which have axle part numbers E4UA-6-BA and E4UA-7-BA embossed on the face of each axle. Three other significant factors may also contribute to outboard shoulder wear. They are excessive toe-in (generally greater than 5/32 inch), excessive cornering speeds, and low tire pressure. After any adjustments to front end alignment, toe should be adjusted to zero. On vehicles subject to extensive city-delivery use, toe may be set up to 1/16 inch toe-out for optimum tire life. PART NUMBER PART NAME CLASS E5TZ-3K064-A Kit Caster Adjustment C OTHER APPLICABLE ARTICLES: 85-19-15 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3360B85T TIME: 4.6 Hrs. OPERATION: 3001A TIME: 0.5 Hr. - Check caster camber and toe-in DLR. CODING: Basic Part No. 3A360 - Code: 36 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 851916 > Sep > 85 > Tires - Front Outside Edge Wear Tires: All Technical Service Bulletins Tires - Front Outside Edge Wear Article No. 85-19-16 TIRE WEAR - FRONT - OUTSIDE EDGE LIGHT TRUCK 1976-86 E100-150 Outboard shoulder wear, predominantly in lightly loaded city-delivery type use, is aggravated by excessive positive wheel camber in turning. The caster adjustment kit described in TSB 85-19-15 can be used to increase caster of either wheel up to 3 degrees in 1/2 degree increments. The kit contains complete instructions for modifying the front radius arms and mounting a metal adjusting cam to the bottom flange of each radius arm. Cams must be arc-welded a minimum of one inch along two sides of the cam to the lower flange of the radius arm. Increasing caster the full 3 degrees effectively reduces camber of the outboard wheel in a turn 1.5 degrees. Increasing caster more than 3 degrees is not recommended since this may cause complaints of wheel shimmy and/or excessive steering efforts. Also, caster should not be increased on vehicles built since April 1, 1984. These vehicles have the 3 degree caster increase already built into the axles which have axle part numbers E4UA-6-BA and E4UA-7-BA embossed on the face of each axle. Three other significant factors may also contribute to outboard shoulder wear. They are excessive toe-in (generally greater than 5/32 inch), excessive cornering speeds, and low tire pressure. After any adjustments to front end alignment, toe should be adjusted to zero. On vehicles subject to extensive city-delivery use, toe may be set up to 1/16 inch toe-out for optimum tire life. PART NUMBER PART NAME CLASS E5TZ-3K064-A Kit Caster Adjustment C OTHER APPLICABLE ARTICLES: 85-19-15 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3360B85T TIME: 4.6 Hrs. OPERATION: 3001A TIME: 0.5 Hr. - Check caster camber and toe-in DLR. CODING: Basic Part No. 3A360 - Code: 36 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 841919 > Sep > 84 > Steering - Pull/Drift Diagnostic Procedures Tires: All Technical Service Bulletins Steering - Pull/Drift Diagnostic Procedures Article No. 84-19-19 STEERING PULL/DRIFT/ROADABILITY - DIAGNOSTIC PROCEDURES LIGHT TRUCKS 1980-84 F100-350, BRONCO, ECONOLINE Section 19 of the 1983 and 1984 Light Truck Shop Manuals provides procedures to resolve most roadability concerns experienced to date. These procedures can be applied to any 1980 and later model light trucks. When servicing 4 wheel drive vehicles with limited slip front axles, front tire circumference is the most probable cause if the pull is only present when the hubs are locked. Installing the two most evenly matched tires on the front axle should resolve the concern. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 841919 > Sep > 84 > Steering - Pull/Drift Diagnostic Procedures Tires: All Technical Service Bulletins Steering - Pull/Drift Diagnostic Procedures Article No. 84-19-19 STEERING PULL/DRIFT/ROADABILITY - DIAGNOSTIC PROCEDURES LIGHT TRUCKS 1980-84 F100-350, BRONCO, ECONOLINE Section 19 of the 1983 and 1984 Light Truck Shop Manuals provides procedures to resolve most roadability concerns experienced to date. These procedures can be applied to any 1980 and later model light trucks. When servicing 4 wheel drive vehicles with limited slip front axles, front tire circumference is the most probable cause if the pull is only present when the hubs are locked. Installing the two most evenly matched tires on the front axle should resolve the concern. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Adjustments Wheel Bearing: Adjustments EXCEPT 4 WHEEL DRIVE MODELS 1. Remove wheel and tire assembly, disc brake caliper and pads, dust cap, locknut, adjusting nut, washer and cotter pin. 2. Tighten wheel adjusting nut to 22-25 ft. lbs. while rotating disc brake rotor in opposite direction. 3. Back off wheel retention nut 1/8 turn and install retainer and cotter pin without any additional movement of nut. 4. Reinstall dust cap, caliper, pads and tire and wheel assembly. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Adjustments > Page 641 Wheel Bearing: Service and Repair EXC. 4 WHEEL DRIVE MODELS 1. Raise and support front of vehicle and remove front wheels. 2. Remove brake caliper and position aside, leaving brake lines attached. Do not allow weight of caliper to hang on brake lines. 3. Remove grease cap, cotter pin, locknut, adjusting nut and washer, then the outer bearing cone and roller. 4. Remove hub and rotor and discard grease retainer. 5. Remove inner bearing and roller. 6. Reverse procedure to install. Adjust bearings as described under ``Wheel Bearings, Adjust''. 4 WHEEL DRIVE MODELS 1. Raise and support front of vehicle and remove front wheels. 2. On models equipped with locking hubs, remove hubs as described in ``Front Wheel Drive Section''. 3. On 1980---81 models, remove front hub grease cap. 4. On 1980---81 models, remove driving hub snap ring, then the splined driving hub and pressure spring. 5. On all models, remove wheel bearing locknut, lock ring and adjusting nut, then the hub and disc assembly. The outer bearing and roller assembly will slide out when the hub is removed. 6. Remove inner bearing and grease seal from wheel hub using a suitable driving tool on 1980---81 models or a puller on 1982---87 models. 7. Reverse procedure to install. Adjust bearings as described under ``Wheel Bearings, Adjust''. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Lug Nuts - Proper Installation/Torqueing Procedure Wheel Fastener: Technical Service Bulletins Lug Nuts - Proper Installation/Torqueing Procedure Article No. 98-5A-4 ^ BRAKES - PREVENTING BRAKE VIBRATION - SERVICE TIP ^ WHEELS - PROPER LUG TORQUE PROCEDURES - SERVICE TIP FORD: 1972-97 THUNDERBIRD 1976-86 LTD 1976-97 MUSTANG 1981-97 CROWN VICTORIA 1982-88 EXP 1982-98 ESCORT 1984-94 TEMPO 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1979-83 MONARCH, ZEPHYR 1979-97 COUGAR 1980-83 MARK VI 1980-98 CONTINENTAL, TOWN CAR 1981-86 LYNX 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-97 SABLE 1987-89 TRACER 1987-97 GRAND MARQUIS 1991-94 CAPRI 1991-97 TRACER 1993-98 MARK VIII 1995-98 MYSTIQUE LIGHT TRUCK: 1979-96 BRONCO 1979-97 ECONOLINE, F-150-350 SERIES 1984-90 BRONCO II 1984-97 RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-98 WINDSTAR 1997 EXPEDITION 1998 NAVIGATOR ISSUE: The use of air impact tools to tighten wheel lug nuts can lead to overtightened and/or unevenly tightened wheel lug nuts. Air impact tools typically used for wheel lug nut removal and installation can generate up to 475 N.m (350 lb-ft) of torque. Overtightened and/or unevenly torqued wheel lug nuts may cause: ^ Brake vibration ^ Distortion of the wheel hub ^ Distortion of the brake rotor Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Lug Nuts - Proper Installation/Torqueing Procedure > Page 646 ^ Brake rotor runout ^ Damage to the wheel ^ Damage to the wheel nuts and studs ACTION: All wheel lug nuts should only be tightened to specification using a torque wrench or by using the Rotunda ACCUTORO 164-R0314 or equivalent on a 1/2" drive air impact tool. The "ACCUTORO" lug nut sockets limit the torque of the air impact tool, preventing overtightening or uneven tightening of the wheel lug nuts. The torque limiting devices (regulators) on air impact tools will not reduce the output torque enough to prevent overtightening of the wheel lug nuts. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Lug Nuts - Proper Installation/Torqueing Procedure > Page 647 NOTE: REFER TO THE APPROPRIATE SERVICE MANUAL OR THE CHART IN FIGURE 1 FOR THE CORRECT WHEEL LUG NUT TORQUE SPECIFICATION. THE CHART IN FIGURE 1 ALSO PROVIDES THE CORRECT "ACCUTORO" LUG NUT SOCKET TO USE. The "ACCUTORO" socket is intended for lug nut installation, not removal. When using the "ACCUTORO" socket, the output torque of the air impact tool must be set to 217-339 N.m (160-250 lb-ft), usually this will be the lowest setting on the air impact tool. The "ACCUTORO" lug nut sockets are available through Rotunda Equipment. The four-piece set (164-R0314) fits most Ford Motor Company cars and light trucks. The tool set consists of four (4) lug nut sockets and a storage case. The set can be ordered by calling Rotunda Equipment at 1-800-ROT-UNDA (768-8632). CAUTION: AIR IMPACT TOOLS SHOULD NOT BE USED TO TIGHTEN WHEEL LUG NUTS UNLESS THE "ACCUTORO" LUG NUT SOCKET OF THE CORRECT SPECIFICATION IS USED. NOTE: DO NOT USE AIR IMPACT TOOLS ON LOCKING WHEEL LUG NUTS. THEY ARE TO BE HAND-TORQUED ONLY. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-17-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 303000, 306000 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > System Diagnosis Compression Check: Testing and Inspection COMPRESSION TEST 1. Ensure oil in crankcase is of the correct viscosity and at proper level and battery is properly charged. Operate vehicle until engine is at normal operating temperature. Turn OFF ignition switch, then remove all spark plugs. 2. Set throttle plates (and choke plates, if equipped) in wide-open position. 3. Install a compression gauge such as Rotunda Compression Tester 059-00009 or equivalent in No. 1 cylinder. 4. Install an auxiliary starter switch in starting circuit. With ignition switch in the OFF position, and using auxiliary starter switch, crank engine at least five compression strokes and record highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat test on each cylinder cranking the engine approximately the same number of compression strokes. TEST CONCLUSION 1. The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest. 2. If one or more cylinders read low, squirt approximately one tablespoon of heavy SAE 50 weight or equivalent engine oil on top of the pistons in the low reading cylinders. Repeat compression pressure check on these cylinders. a. If compression improves considerably, piston rings are at fault. b. If compression does not improve, valves are sticking or seating poorly. c. If two adjacent cylinders indicate low compression pressures and squirting oil on pistons does not increase compression, cause may be a cylinder head gasket leak between cylinders. Engine oil and/or coolant in cylinders could result from this problem. Compression Pressure Limit Chart NOTE: Refer to the compression pressure limit chart for pressure specifications. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications Camshaft: Specifications Camshaft Clearance Specifications Camshaft Clearance Specifications Camshaft Journal Diameter No. 1 2.0805-2.0815 in No. 2 2.0655-2.0665 in No. 3 2.0505-2.0515 in No. 4 2.0355-2.0365 in No. 5 2.0205-2.0215 in Camshaft Bearing Inside Diameter No. 1 2.0825-2.0835 in No. 2 2.0675-2.0685 in No. 3 2.0525-2.0535 in No. 4 2.0375-2.0385 in No. 5 2.0225-2.0235 in Camshaft Bearing Clearance .001-.003 in Note: Service Limit -- 0.006 in Camshaft End Play .001-.007 in Note: Service Limit -- 0.009 in Camshaft Runout Max. 0.005 in Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 657 Camshaft: Service and Repair V8 ENGINES 1. On Econoline models except V8-351M and 400 engines, remove grille. 2. On all models, drain cooling system, then disconnect all lines and hoses from radiator and remove radiator. 3. Remove intake manifold, then the rocker arm covers. 4. Loosen rocker arms, then remove pushrods and valve lifters in sequence. 5. Remove timing case cover and timing chain as previously described. 6. On models equipped with A/C, remove A/C condenser attaching bolts and position condenser aside. 7. On all models, remove camshaft thrust plate and carefully slide camshaft out through front of engine. 8. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Specifications Lifter / Lash Adjuster: Specifications Lifter Bore Diameter .8752-.8767 in Lifter Diameter .8740-.8745 in Lifter To Bore Clearance .0007-.0027 in Note: Service Limit -- 0.005 in Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Specifications > Page 661 Lifter / Lash Adjuster: Service and Repair V6-232, V8-255, 302, 351, 400, & 460 1. Remove intake manifold. 2. Remove rocker arm covers. Loosen rocker arm stud nuts or bolts and rotate rocker arms to the side. 3. Remove pushrods in sequence so they can be installed in their original bores. 4. Using a magnet, remove the lifters and place them in a numbered rack so they can be installed in their original bores. If lifters are stuck in their bores, it may be necessary to use a plier-type tool to remove them. 5. The internal parts of each lifter are matched sets. Do not intermix parts. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Rocker Arm To Cylinder Head Bolts 18-25 ft.lb Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Specifications > Page 665 Rocker Arm Assembly: Service and Repair Fig. 23 Rocker arm assembly Fig. 24 Rocker Arm Assembly V6-232, V8-255, 302, 351M, 351W, 400 & 460 & 1985-87 6-300 The rocker arm is supported by a fulcrum bolt which fits through the fulcrum seat and threads into the cylinder head. To disassemble, remove the bolt, oil deflector, fulcrum seat and rocker arm, Figs. 26 and 27. 1981-82 models equipped with V8-255, 302 and 351W engines with low profile rocker arm fulcrums (part No. E1TZ-6A528-A) may experience excessive oil displacement when engine is operated for extended periods during high ambient temperatures. This problem may be corrected by replacing original rocker arm fulcrums with part No. D7AZ-6A528-A. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications Connecting Rod: Specifications Connecting Rod Cap Bolts 40-45 ft.lb Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 670 Connecting Rod: Service and Repair Fig. 28 Piston & rod assembly Fig. 29 Piston & rod assembly Fig. 35 Piston & rod assembly. V6-232 Lubricate all parts with light engine oil. Position the connecting rod in the piston and push the pin into place, Figs. 33, 34 and 35. Insert new piston pin retainers (when used) by spiralling them into the piston with the fingers. Do not use pliers. Replacement pistons for the following 6-300 equipped vehicles have an increased ring land, which raises the top compression ring .035 inch: Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 671 1980-81 E & F-100-250 & Bronco except heavy duty. Before installing the new piston, the cylinder ridge must be removed to ensure that the top compression ring does not contact the ridge or deposits formed at the top of the cylinder bore. When removing the ridge, do not cut into the ring travel area more than {1/32} inch. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications Main Cap Torque Main Cap Torque Main Bearing Cap Bolts 95- 105 ft.lb Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft Pulley 70-90 ft.lb Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Piston Diameter coded red 3.9978 - 3.9984 in coded blue 3.9990 - 3.9996 in Piston Clearance .0018-.0026 in Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 681 Piston: Service and Repair Fig. 28 Piston & rod assembly Fig. 29 Piston & rod assembly Fig. 35 Piston & rod assembly. V6-232 Lubricate all parts with light engine oil. Position the connecting rod in the piston and push the pin into place, Figs. 33, 34 and 35. Insert new piston pin retainers (when used) by spiralling them into the piston with the fingers. Do not use pliers. Replacement pistons for the following 6-300 equipped vehicles have an increased ring land, which raises the top compression ring .035 inch: Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications > Page 682 1980-81 E & F-100-250 & Bronco except heavy duty. Before installing the new piston, the cylinder ridge must be removed to ensure that the top compression ring does not contact the ridge or deposits formed at the top of the cylinder bore. When removing the ridge, do not cut into the ring travel area more than {1/32} inch. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Specifications Piston Pin: Specifications Piston Pin Diameter .9119-.9124 in Pin to Piston Bore Clearance .0003-.0005 in Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications End Gap, Compression Ring 0.01 in End Gap, Oil Ring 0.01 in Side Clearance, Top Compression Ring 0.0019 - 0.0036 in Side Clearance, Second Compression Ring 0.002 - 0.004 in Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications Valve Clearance: Specifications ENGINE YEAR CLEARANCE V6-232 82-83 .088-.189 V8-255 81-82 .123-.173 6-300 80-87 .125-.175 V8-302 80-87 .096-.165 V8-351M 80-81 .125 V8-351W 80-87 .123-.173 V8-400 80-82 .175 V8-460 80-87 .100-.150 On engines with hydraulic lifters, clearance specified is at valve stem tip with lifter collapsed. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications > Page 693 Valve Clearance: Locations FRONT TO REAR 6-300 E-I-E-I-E-I-E-I-E-I-E-I V6-232 Right I-E-I-E-I-E V6-232 Left E-I-E-I-E-I V8-255, 302 Left Bank E-I-E-I-E-I-E-I V8-255, 302 Right Bank I-E-I-E-I-E-I-E V8-351, 400 Right Bank I-E-I-E-I-E-I-E V8-351, 400 Left Bank E-I-E-I-E-I-E-I V8-460 Left Bank E-I-E-I-E-I-E-I V8-460 Right Bank I-E-I-E-I-E-I-E Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Specifications > Page 694 Valve Clearance: Adjustments Fig. 21 Compressing valve lifter with tool to check clearance on engines with hydraulic valve lifters V8 ENGINES To provide a means to compensate for dimensional changes in the valve train and provide for valve adjustment, .060 inch shorter or longer pushrods are available. If the valve clearance is less than the minimum, the .060 inch shorter pushrod should be used. If the clearance is more than the maximum, the longer pushrod should be used. To check the valve clearance, proceed as follows: 1. Mark crankshaft pulley at three locations, with No. 1 location at TDC timing mark (end of compression stroke), location No. 2 one full turn (360°) clockwise from TDC and No. 3 location one quarter turn clockwise (90°) from position No. 2. 2. Turn crankshaft to number 1 location, then compress valve lifter using tool T71P-6513-A or equivalent, Fig. 21, and check the clearance on the following valves: V8-255, 302, 460 No. 1 Intake No. 1 Exhaust No. 7 Intake No. 5 Exhaust No. 8 Intake No. 4 Exhaust V8-351 & 400 No. 1 Intake No. 1 Exhaust No. 4 Intake No. 3 Exhaust No. 8 Intake No. 7 Exhaust 3. Turn crankshaft to number 2 location, then compress valve lifter using tool T71P-6513-A or equivalent, Fig. 21, and check the clearance on the following valves: V8-255, 302, 460 No. 5 Intake No. 2 Exhaust No. 4 Intake No. 6 Exhaust V8-351 & 400 No. 3 Intake No. 2 Exhaust No. 7 Intake No. 6 Exhaust 4. Turn crankshaft to number 3 location, then compress valve lifter using tool T71P-6513-A or equivalent, Fig. 21, and check the clearance on the following valves: V8-255, 302, 460 No. 2 Intake No. 7 Exhaust No. 3 Intake No. 3 Exhaust No. 6 Intake No. 8 Exhaust V8-351 & 400 No. 2 Intake No. 4 Exhaust No. 5 Intake No. 5 Exhaust No. 6 Intake No. 8 Exhaust Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications Rocker Arm Assembly: Specifications Rocker Arm To Cylinder Head Bolts 18-25 ft.lb Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Specifications > Page 698 Rocker Arm Assembly: Service and Repair Fig. 23 Rocker arm assembly Fig. 24 Rocker Arm Assembly V6-232, V8-255, 302, 351M, 351W, 400 & 460 & 1985-87 6-300 The rocker arm is supported by a fulcrum bolt which fits through the fulcrum seat and threads into the cylinder head. To disassemble, remove the bolt, oil deflector, fulcrum seat and rocker arm, Figs. 26 and 27. 1981-82 models equipped with V8-255, 302 and 351W engines with low profile rocker arm fulcrums (part No. E1TZ-6A528-A) may experience excessive oil displacement when engine is operated for extended periods during high ambient temperatures. This problem may be corrected by replacing original rocker arm fulcrums with part No. D7AZ-6A528-A. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Valve Cover Gasket > Component Information > Technical Service Bulletins > Seals For Rocker Cover, Oil Pan, and Crankshaft Valve Cover Gasket: Technical Service Bulletins Seals For Rocker Cover, Oil Pan, and Crankshaft Article No. 83-13-6 LEAKS - OIL - CURRENT SEALS FOR ROCKER COVER, OIL PAN, AND CRANKSHAFT FORD 1983 AND PRIOR LINCOLN-MERCURY 1983 AND PRIOR LIGHT TRUCKS 1983 AND PRIOR MEDIUM/HEAVY TRUCKS 1983 AND PRIOR The following charts outline current gasket identification for rocker cover, oil pan, and crankshaft seal applications to provide the most effective sealing. Those rocker cover and oil pan applications that use "High Swell Material" are shown by an asterisk (* ). ROCKER COVER GASKETS Engine Year Part Number Class 1.6L 1981-83 E3FZ-6584-A* A 2.3L 1977-83 E2ZZ-6584-A A 3.3L 1977-83 E3BZ-6584-A* A 4.1L 1977-80 E3BZ-6584-A* A 3.8L 1982-83 RTV 1983 E3DZ-6584-A* A w/metal rocker cover 4.2L 1980-82 E3AZ-6584-A* A 4.9L 1977-83 E3TZ-6584-C* A 5.0L, 5.0L HO 1977-83 E3AZ-6584-A* A 5.8L (W) 1977-83 E3AZ-6584-A* A 5.8L (M) 1980-82 D00Z-6584-A A 6.6L 1973-79 D00Z-6584-A A 6.1L 1983 E3TZ-6584-E* A 7.0L 1980-82 E3TZ-6584-E* A 7.5L 1979-79 E3TZ-6584-E* A OIL PAN GASKETS Engine Year Part Number Class 1.6L 1981-83 E1FZ-6781-A A 2.3L 1977-83 E2ZZ-6781-A AM 3.3L 1977-83 D0DZ-6781-A* A 3.8L 1982-83 RTV 4.1L 1977-80 D0DZ-6781-B A 4.2 1980-82 D9AZ-6781-A A 4.9L 1977-83 E3TZ-6781-B* A 5.0L 1977-83 D9AZ-6781-A A 5.8L (W) 1977-83 D0AZ-6781-C* A 5.8L (M), 6.6L 1977-82 D0AZ-6781-D A 6.1L 1983 D9HZ-6781-A AQ 7.0L 1982 D9HZ-6781-A AQ 7.5L 1977-81 E0UZ-6781-A A *High Swell Material. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Valve Cover Gasket > Component Information > Technical Service Bulletins > Seals For Rocker Cover, Oil Pan, and Crankshaft > Page 704 ARTICLE SUPERSEDED:83-5-7WARRANTY STATUS:"INFORMATION ONLY" CRANKSHAFT SEAL Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications Valve Guide: Specifications Guide, Inside Diameter .3433-.3443 in Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Specifications > Page 708 Valve Guide: Service and Repair Valve guides in these engines are an integral part of the head and, therefore, cannot be removed. For service, guides can be reamed oversize to accommodate one of three service valves with oversize stems (.003 inch, .015 inch and .030 inch). Check the valve stem clearance of each valve (after cleaning) in its respective valve guide. If the clearance exceeds the service limits of .004 inch of the intake or .005 inch on the exhaust, ream the valve guides to accommodate the next oversize diameter valve. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component Information > Specifications Valve Seat: Specifications Seat Width, Intake .060-.080 in Seat Width, Exhaust .060-.080 in Runout 0.002 in Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Specifications Valve Spring: Specifications Free Length Intake 2.04 in Free Length Exhaust 1.85 in Out Of Square Limit 0.078 in Installed Height Intake 1.765-1.797 in Installed Height Exhaust 1.578-1.609 in Spring Pressure, Closed, Intake 74-82 lbf at 1.78 in Spring Pressure, Closed, Exhaust 76-84 lbf at 1.60 in Spring Pressure, Open, Intake 190-210 lbf at 1.36 in Spring Pressure, Open, Exhaust 190-210 lbf at 1.20 in Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Specifications Valve: Specifications Stem Diameter Intake .3416-.3423 in Stem Diameter Exhaust .3411-.3418 in Maximum Tip Refinish 0.01 in Face Angle 44 deg Margin Intake 1/32 in Margin Exhaust 1/32 in Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications Drive Belt: Specifications A belt in operation 10 minutes is considered a used belt. 1988-89 Automatic tensioner used. Deflection method: Table lists deflection at midpoint of belt segment. Strand Tension method: Use a strand tension gauge. Measurements are in pounds. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Specifications > Page 722 Drive Belt: Adjustments A belt in operation 10 minutes is considered a used belt. 1988-89 Automatic tensioner used. Deflection method: Table lists deflection at midpoint of belt segment. Strand Tension method: Use a strand tension gauge. Measurements are in pounds. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair Engine Mount: Service and Repair Fig. 6 Engine mounts. E-100---350 w/V8-302, 351W engine V8-302 & 351W E-100-350 1. Remove fan shroud attaching bolts and the insulator-to-support nuts. 2. Raise engine assembly and remove starter motor. 3. Remove insulator attaching bolts, then the alternator splash shield and insulator, Fig. 6. 4. Reverse procedure to install. Fig. 9 Engine mounts. 1980---82 E-100---350 w/V8-351M, 400 engine 1980-82 E-100-350 1. Remove fan shroud attaching bolts and the insulator-to-support nuts. 2. Raise engine slightly and remove starter motor. When raised, the engine and transmission assembly will pivot around the rear engine mount. The engine assembly must be lifted exactly two inches, measured from front mounts, and remain centered in the engine compartment. If Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Page 726 the engine is lifted more than two inches, the A/C main and auxiliary lines will be damaged. 3. Remove insulator attaching bolts, then the alternator splash shield and insulator, Fig. 9. 4. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine - Oil Level Checking Procedure Engine Oil: Technical Service Bulletins Engine - Oil Level Checking Procedure Article No. 85-25-20 OIL DIPSTICK - ENGINE OIL LEVEL CHECKING PROCEDURE - GASOLINE ENGINES LIGHT TRUCK 1986 AND PRIOR MEDIUM/HEAVY TRUCK 1986 AND PRIOR Figure 17 - Dipstick To correctly check the engine oil level, the vehicle must be parked on a level surface. Allow a few minutes after shutting the engine off for oil to drain down before checking. For consistent oil level readings, insert the dipstick with the loop of the handle as shown in Figure 17. Figure 18 - Dipstick - Calibration Figure 19 - Dipstick - Calibration Dipsticks in Ford vehicles do not incorporate a Full mark. Instead, the dipstick will have marks indicating a Safe range and an Add range as shown in Figure 18 or 19. When the correct amount of oil is in the engine, the oil level indication will be in the Safe range or above the Minimum mark, but not necessarily at the top of the Safe range or at the Maximum mark. When the indicated oil level is in the Add range put one quart of oil in the engine. Recheck the oil level to determine if the oil level is now in the Safe range or above the Minimum mark. Add and recheck oil level one quart at a time until the oil level indicator moves into the Safe range or above the Minimum mark. Do not add additional oil to bring the level to the top of the Safe range or to the Maximum mark since this may result in overfill and increased oil consumption. If the accuracy of the engine oil dipstick is in doubt, it may be verified in the following manner: ^ Drain the oil and install a new filter. ^ Put in the specified amount of oil for an oil and filter change. (See owner guide) ^ Start the engine and operate a few minutes. ^ Shut off the engine and allow a few minutes for the oil to drain down. ^ Check the oil level with the dipstick. ^ If the oil level does not indicate in the Safe range or above the Minimum mark, rework or replace the dipstick. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine oil capacity ............................................................................................................................... ........................................................... 5.0 Qts.(4.7L) Note: Add 1 Qt. with filter change. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 734 Engine Oil: Fluid Type Specifications BL Self-adjusting Brake Lubricant EC Ethylene Glycol Coolant Mix 50/50 with water to at least -20°F (-29°C) protection EP Extreme Pressure Gear Lubricant Ford Part No. D8DZ-19C547-A FA Automatic Transmission Fluid, Type F GL-5 Gear Oil, API Service GL-5 HBH Hydraulic Brake Fluid, Extra Heavy-Duty HP Hypoid Gear Oil Ford Part No. E0AZ-19580-A HP* Hypoid Gear Oil for Limited-Slip or Traction-Lok Differential LM Lithium Grease, with Polyethylene LS Steering Gear Lubricant MA MERCONAutomatic Transmission Fluid MH Manifold Heat Valve Solvent SG Motor Oil, API Service SG Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair Oil Pan: Service and Repair ECONOLINE V8-302 & 351W 1. Disconnect battery ground cable. 2. Remove engine cover and air cleaner, then drain cooling system. 3. On models equipped with power steering, remove steering pump drive belt, then unfasten pump and position aside. 4. On models equipped with A/C, unfasten A/C compressor and position aside. 5. On all models, disconnect upper radiator hose, then remove fan shroud attaching bolts, oil filler tube and oil dipstick-to-exhaust manifold attaching bolt. 6. Raise and support vehicle. 7. Remove alternator splash shield, then disconnect lower radiator hose. 8. On models equipped with automatic transmission, disconnect oil cooler lines from radiator. 9. On all models, disconnect fuel line from fuel pump, then remove engine mount attaching nuts. 10. Drain engine oil, then remove dipstick tube from oil pan. 11. Disconnect exhaust pipes from exhaust manifolds. 12. On models equipped with automatic transmission, remove transmission oil dipstick and tube. 13. On all models, disconnect manual linkage from transmission, then remove center driveshaft support and driveshaft from transmission. 14. Raise engine and transmission assembly using a suitable jack and a wooden block. Position wooden blocks to support engine at uppermost position, then lower engine to rest on blocks. When raised, the engine and transmission assembly will pivot around the rear engine mount. The engine assembly must be lifted exactly four inches, measured from front mounts, and remain centered in the engine compartment. 15. Remove oil pan attaching bolts and lower the pan. 16. On all except 1981-87 models equipped with V8-351W engine, remove oil pump and pickup tube assembly and lay in oil pan. 17. On all models, remove oil pan from vehicle. 18. Reverse procedure to install. Engine oiling system. V8-302, 351, 400 1980-82 ECONOLINE V8-351M & 400 1. Perform steps 1 thru 8 as described under ``Econoline V8-255, 302 & 351W.'' 2. Position suitable jack under oil pan and place 1{3/4} inch block of wood between pan and jack. Raise engine 2 inches. Do not raise engine more than 2 inches, as damage to the air conditioner system will result. 3. Position wood blocks under engine mounts, then lower engine onto mounts. 4. Remove oil pan from vehicle. 5. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Testing and Inspection Oil Pressure Gauge: Testing and Inspection This oil pressure indicating system incorporates an instrument voltage regulator, electrical oil pressure gauge and a sending unit which are connected in series. The sending unit consists of a diaphragm, contact and a variable resistor. As oil pressure increases or decreases, the diaphragm actuated the contact on the variable resistor, in turn controlling current flow to the gauge. When oil pressure is low, the resistance of the variable resistor is high, restricting current flow to the gauge, in turn indicating low oil pressure. As oil pressure increases, the resistance of the variable resistor is lowered, permitting an increased current flow to the gauge, resulting in an increased gauge reading. TROUBLESHOOTING A special tester is required to diagnose this type gauge. Follow instructions included with the tester. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Switch <--> [Oil Pressure Sender] > Component Information > Locations Oil Pressure Switch: Locations LH Lower Front Of Engine Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Testing and Inspection Oil Pressure Warning Lamp/Indicator: Testing and Inspection Many trucks utilize a warning light on the instrument panel in place of the conventional dash indicating gauge to warn the driver when the oil pressure is dangerously low. The warning light is wired in series with the ignition switch and the engine unit--which is an oil pressure switch. The oil pressure switch contains a diaphragm and a set of contacts. When the ignition switch is turned on, the warning light circuit is energized and the circuit is completed through the closed contacts in the pressure switch. When the engine is started, build-up of oil pressure compresses the diaphragm, opening the contacts, thereby breaking the circuit and putting out the light. TROUBLESHOOTING The oil pressure warning light should go on when the ignition is turned on. If it does not light, disconnect the wire from the engine unit and ground the wire to the frame or cylinder block. Then if the warning light still does not go on with the ignition switch on, replace the bulb. If the warning light goes on when the wire is grounded to the frame or cylinder block, the engine unit should be checked for being loose or poorly grounded. If the unit is found to be tight and properly grounded, it should be removed and a new one installed. (The presence of sealing compound on the threads of the engine unit will cause a poor ground). If the warning light remains lit when it normally should be out, replace the engine unit before proceeding further to determine the cause for a low pressure indication. The warning light will sometimes light up or flicker when the engine is idling, even though the oil pressure is adequate. However, the light should go out when the engine speed is increased. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component Information > Specifications Oil Pump: Specifications Rotor Backlash 0.012 in Note: Maximum inner and outer rotor tip clearance. Rotor To Body Clearance 0.001-0.003 in Rotor End Clearance 0.004 in Note: Measured between pump cover mounting surface & end of gear using suitable straightedge & feeler gauges. Maximum Maximum Cover Flatness Variation N/A Note: Pump should be replaced if cover is damaged, scored or worn. Driveshaft To Pump Body Clearance 0.0015-0.0030 in Relief Valve To Body Clearance 0.0015-0.0030 in Relief Spring Pressure 18.2-20.2 lbf at 2.49 in Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component Information > Service and Repair > Removal and Installation Oil Pump: Service and Repair Removal and Installation V8 ENGINES On some models, the oil pump must be removed when removing the oil pan. These models are indicated in the ``Oil Pan, Replace'' procedures. 1. Remove oil pan as previously described. 2. Remove oil pump attaching bolts and the oil pump. 3. To install, prime pump with engine oil and apply sealant to gasket. 4. Insert distributor intermediate shaft, making sure that it is properly seated, then install oil pump. Do not force pump into place if it will not readily seat, as the intermediate shaft may be misaligned with distributor shaft. To align, rotate intermediate shaft until pump can be seated without applying force. 5. Install oil pan. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component Information > Service and Repair > Removal and Installation > Page 752 Oil Pump: Service and Repair Service Fig. 42 Oil pump. 6-300 Fig. 43 Oil pump. V8-255, 302, 351W Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component Information > Service and Repair > Removal and Installation > Page 753 Fig. 44 Oil pump assembly. 351M & 400 ROTOR TYPE PUMP 1. To disassemble, Figs. 42, 43 and 44, remove cover, inner rotor and shaft assembly and outer race. Remove staking marks at relief valve chamber cap. Insert a self-threading sheet metal screw of proper diameter into oil pressure relief valve chamber cap and pull cap out of chamber. Then remove spring and plunger. 2. To assemble, install pressure relief valve plunger, spring and a new cap. Stake cap in place. Install outer race, inner rotor and shaft. Be sure identification dimple mark on outer race is facing outward and on the same side as dimple on rotor. Inner rotor and shaft and outer race are furnished only as a unit. One part should not be replaced without replacing the other. 3. Install pump cover. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Service Labor Time Standards Revision Intake Manifold: Technical Service Bulletins Service Labor Time Standards Revision REVISED SERVICE LABOR TIME STANDARDS Article No. 87-8-20 LIGHT TRUCK: 1981-84 F-100/350, ECONOLINE, BRONCO ISSUE: Labor operations 9424A, (Intake manifold - remove and install or replace) and 9631A (Accelerator pump diaphragm or piston rod (carburetor) - replace) have been revised. ACTION: The new labor allowances are as follows: Operation 9424A Intake Manifold - Remove and Install or Replace New allowance for 1981-84 Econoline (5.0L and 5.8L) . . . . . . . . . . . . . . . . . . . . 3.2 Hrs. Operation 9631A Accelerator Pump, Diaphragm or Piston Rod (Carburetor) - Replace New allowance for all 8-cyl. engines (1984 only) . . . . . . . . . . . . . . . . . . . . . . 1.3 Hrs. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 758 Intake Manifold: Specifications Intake Manifold 23-25 ft.lb Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 759 Intake Manifold: Service and Repair Fig. 13 Intake manifold tightening sequence. V8-255, 302 & V8-351W Fig. 20 Intake manifold installation. V8 engines V8-255, 302 & 351W 1. Drain cooling system, then remove air cleaner with intake duct assembly and crankcase ventilation hose. 2. Disconnect accelerator cable and speed control linkage (if equipped) from carburetor or throttle body. Remove accelerator cable bracket, then disconnect kickdown rod from carburetor or throttle body on models equipped with automatic transmission. Disconnect electric choke, carburetor solenoid electrical connectors or EEC connector, if equipped. 3. Disconnect high tension lead and wires from ignition coil. 4. Disconnect ignition wires from spark plugs, then remove wires and bracket assembly from rocker arm cover attaching stud. 5. Remove distributor cap and ignition wires as an assembly. 6. Disconnect fuel inlet line from carburetor or throttle body. 7. Disconnect vacuum hoses from distributor, then remove distributor and disconnect evaporative hoses, if equipped. 8. Disconnect upper radiator hose from coolant outlet housing. 9. Disconnect electrical connector from coolant temperature sending unit, then remove heater hose from intake manifold. 10. Remove water pump bypass hose from coolant outlet housing, then disconnect crankcase vent hose from rocker arm cover. 11. Remove intake manifold attaching bolts, then the intake manifold, carburetor or throttle body as an assembly. 12. Reverse procedure to install. Apply sealer as shown in Fig. 20. Torque manifold attaching bolts to 23-25 ft-lbs in sequence as shown in Fig. 13. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Testing and Inspection Oil Pressure Gauge: Testing and Inspection This oil pressure indicating system incorporates an instrument voltage regulator, electrical oil pressure gauge and a sending unit which are connected in series. The sending unit consists of a diaphragm, contact and a variable resistor. As oil pressure increases or decreases, the diaphragm actuated the contact on the variable resistor, in turn controlling current flow to the gauge. When oil pressure is low, the resistance of the variable resistor is high, restricting current flow to the gauge, in turn indicating low oil pressure. As oil pressure increases, the resistance of the variable resistor is lowered, permitting an increased current flow to the gauge, resulting in an increased gauge reading. TROUBLESHOOTING A special tester is required to diagnose this type gauge. Follow instructions included with the tester. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Testing and Inspection Oil Pressure Warning Lamp/Indicator: Testing and Inspection Many trucks utilize a warning light on the instrument panel in place of the conventional dash indicating gauge to warn the driver when the oil pressure is dangerously low. The warning light is wired in series with the ignition switch and the engine unit--which is an oil pressure switch. The oil pressure switch contains a diaphragm and a set of contacts. When the ignition switch is turned on, the warning light circuit is energized and the circuit is completed through the closed contacts in the pressure switch. When the engine is started, build-up of oil pressure compresses the diaphragm, opening the contacts, thereby breaking the circuit and putting out the light. TROUBLESHOOTING The oil pressure warning light should go on when the ignition is turned on. If it does not light, disconnect the wire from the engine unit and ground the wire to the frame or cylinder block. Then if the warning light still does not go on with the ignition switch on, replace the bulb. If the warning light goes on when the wire is grounded to the frame or cylinder block, the engine unit should be checked for being loose or poorly grounded. If the unit is found to be tight and properly grounded, it should be removed and a new one installed. (The presence of sealing compound on the threads of the engine unit will cause a poor ground). If the warning light remains lit when it normally should be out, replace the engine unit before proceeding further to determine the cause for a low pressure indication. The warning light will sometimes light up or flicker when the engine is idling, even though the oil pressure is adequate. However, the light should go out when the engine speed is increased. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > Seals For Rocker Cover, Oil Pan, and Crankshaft Crankshaft Main Bearing Seal: Technical Service Bulletins Seals For Rocker Cover, Oil Pan, and Crankshaft Article No. 83-13-6 LEAKS - OIL - CURRENT SEALS FOR ROCKER COVER, OIL PAN, AND CRANKSHAFT FORD 1983 AND PRIOR LINCOLN-MERCURY 1983 AND PRIOR LIGHT TRUCKS 1983 AND PRIOR MEDIUM/HEAVY TRUCKS 1983 AND PRIOR The following charts outline current gasket identification for rocker cover, oil pan, and crankshaft seal applications to provide the most effective sealing. Those rocker cover and oil pan applications that use "High Swell Material" are shown by an asterisk (* ). ROCKER COVER GASKETS Engine Year Part Number Class 1.6L 1981-83 E3FZ-6584-A* A 2.3L 1977-83 E2ZZ-6584-A A 3.3L 1977-83 E3BZ-6584-A* A 4.1L 1977-80 E3BZ-6584-A* A 3.8L 1982-83 RTV 1983 E3DZ-6584-A* A w/metal rocker cover 4.2L 1980-82 E3AZ-6584-A* A 4.9L 1977-83 E3TZ-6584-C* A 5.0L, 5.0L HO 1977-83 E3AZ-6584-A* A 5.8L (W) 1977-83 E3AZ-6584-A* A 5.8L (M) 1980-82 D00Z-6584-A A 6.6L 1973-79 D00Z-6584-A A 6.1L 1983 E3TZ-6584-E* A 7.0L 1980-82 E3TZ-6584-E* A 7.5L 1979-79 E3TZ-6584-E* A OIL PAN GASKETS Engine Year Part Number Class 1.6L 1981-83 E1FZ-6781-A A 2.3L 1977-83 E2ZZ-6781-A AM 3.3L 1977-83 D0DZ-6781-A* A 3.8L 1982-83 RTV 4.1L 1977-80 D0DZ-6781-B A 4.2 1980-82 D9AZ-6781-A A 4.9L 1977-83 E3TZ-6781-B* A 5.0L 1977-83 D9AZ-6781-A A 5.8L (W) 1977-83 D0AZ-6781-C* A 5.8L (M), 6.6L 1977-82 D0AZ-6781-D A 6.1L 1983 D9HZ-6781-A AQ 7.0L 1982 D9HZ-6781-A AQ 7.5L 1977-81 E0UZ-6781-A A *High Swell Material. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > Seals For Rocker Cover, Oil Pan, and Crankshaft > Page 772 ARTICLE SUPERSEDED:83-5-7WARRANTY STATUS:"INFORMATION ONLY" CRANKSHAFT SEAL Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > Seals For Rocker Cover, Oil Pan, and Crankshaft > Page 773 Crankshaft Main Bearing Seal: Technical Service Bulletins Crankshaft Seal - Leaks, Air Pressure Test Article No. 86-3-14 LEAK OIL - CRANKSHAFT SEAL - AIR PRESSURE TEST FORD 1986 and Prior FORD, THUNDERBIRD, LTD, ESCORT, FAIRMONT, MUSTANG, EXP, TAURUS LINCOLN-MERCURY 1986 and Prior LINCOLN, MARK, CONTINENTAL, MERCURY, MARQUIS, COUGAR, CAPRI, LYNX, LN7, SABLE LIGHT TRUCK 1986 and Prior RANGER, BRONCO II, AEROSTAR, E AND F SERIES To prevent repeat servicing on engines suspected of oil leakage at the crankshaft seal, determine if the leak is actually from the seal or from another source such as the rear pan seal or galley plugs. The one-piece rear crankshaft seal is released for all passenger car and light truck engines and has proven to be more reliable than the rope or split lip design formerly used. Performing the oil leak air pressure check outlined in all Car and Truck Powertrain Shop Manuals, Section 21- 01 will accurately identify the location of the leak and can verify correction after servicing before the transmission is reinstalled. OTHER APPLICABLE ARTICLES: 80-15-5, 83-14-8 WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > Page 774 Crankshaft Main Bearing Seal: Specifications Main Bearing Cap Bolt Torque ................................................................................................................................................. 129-142 Nm (95-105 ft-lbs) Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Removal Crankshaft Main Bearing Seal: Service and Repair Removal A split lip-type crankshaft rear oil seal is provided for servicing these engines. 1. Remove the oil pan and the oil pump, if required. 2. Loosen all the crankshaft main bearing cap bolts, thereby lowering the crankshaft slightly but not to exceed 0.794 mm (1/32 inch). CAUTION: Use care to prevent scratching or damaging the crankshaft sealing surfaces. 3. Remove the rear crankshaft main bearing cap, and remove the crankshaft rear oil seal from the rear crankshaft main bearing cap and cylinder block. On the cylinder block half of the crankshaft rear oil seal use a seal removal tool, or install a small metal screw in one end of the crankshaft rear oil seal, and PULL on the screw to remove the crankshaft rear oil seal. 4. Remove the oil seal retaining pin from the bearing cap if so equipped. The pin is not used with the split-lip seal. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Removal > Page 777 Crankshaft Main Bearing Seal: Service and Repair Installation 1. Carefully clean the seal groove in the rear crankshaft main bearing cap and cylinder block with a brush and solvent such as lacquer thinner, Extra Strength Spot and Stain Remover. Also, clean the area where sealer is later to be applied. Dry the area thoroughly, so that no solvent touches the crankshaft rear oil seal. 2. Dip the split lip-type seal halves in clean engine oil. CAUTION: Be sure no rubber has been shaved from the outside diameter of the crankshaft rear oil seal by the bottom edge of the groove. Do not allow oil to get on the sealer area. 3. Carefully install the upper half of the crankshaft rear oil seal (cylinder block) into its groove with undercut side of crankshaft rear oil seal toward the FRONT of the engine, by ROTATING it on the seal journal of the crankshaft until approximately 9.53 mm (3/8 inch) protrudes below the parting surface. 4. Tighten the remaining crankshaft main bearing cap bolts to specifications. Crankshaft rear oil seal installation Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair > Removal > Page 778 5. Install the lower half of the crankshaft rear oil seal in the rear crankshaft main bearing cap with undercut side of crankshaft rear oil seal toward the FRONT of the engine. Allow the crankshaft rear oil seal to protrude approximately 9.53 mm (3/8 inch) above the parting surface to mate with the upper half of the crankshaft rear oil seal when the rear crankshaft main bearing cap is installed. 6. Apply a continuous even 1.59 mm (1/16 inch) diameter bead of RTV Silicone Rubber Sealer or equivalent to the areas shown in the image, following the procedures given in the illustration. NOTE: When applying rubber silicone always use the bead size specified and join the components within 15 minutes of application. After this amount of time the sealant begins to "set-up" and its sealing effectiveness may be reduced. 7. Install the rear crankshaft main bearing cap. Tighten the bolts to specifications. 8. Install the oil pump and oil pan. Fill the crankcase with the proper amount and type of oil. 9. Operate the engine and check for oil leaks. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Oil Pan Gasket, Engine > Component Information > Technical Service Bulletins > Seals For Rocker Cover, Oil Pan, and Crankshaft Oil Pan Gasket: Technical Service Bulletins Seals For Rocker Cover, Oil Pan, and Crankshaft Article No. 83-13-6 LEAKS - OIL - CURRENT SEALS FOR ROCKER COVER, OIL PAN, AND CRANKSHAFT FORD 1983 AND PRIOR LINCOLN-MERCURY 1983 AND PRIOR LIGHT TRUCKS 1983 AND PRIOR MEDIUM/HEAVY TRUCKS 1983 AND PRIOR The following charts outline current gasket identification for rocker cover, oil pan, and crankshaft seal applications to provide the most effective sealing. Those rocker cover and oil pan applications that use "High Swell Material" are shown by an asterisk (* ). ROCKER COVER GASKETS Engine Year Part Number Class 1.6L 1981-83 E3FZ-6584-A* A 2.3L 1977-83 E2ZZ-6584-A A 3.3L 1977-83 E3BZ-6584-A* A 4.1L 1977-80 E3BZ-6584-A* A 3.8L 1982-83 RTV 1983 E3DZ-6584-A* A w/metal rocker cover 4.2L 1980-82 E3AZ-6584-A* A 4.9L 1977-83 E3TZ-6584-C* A 5.0L, 5.0L HO 1977-83 E3AZ-6584-A* A 5.8L (W) 1977-83 E3AZ-6584-A* A 5.8L (M) 1980-82 D00Z-6584-A A 6.6L 1973-79 D00Z-6584-A A 6.1L 1983 E3TZ-6584-E* A 7.0L 1980-82 E3TZ-6584-E* A 7.5L 1979-79 E3TZ-6584-E* A OIL PAN GASKETS Engine Year Part Number Class 1.6L 1981-83 E1FZ-6781-A A 2.3L 1977-83 E2ZZ-6781-A AM 3.3L 1977-83 D0DZ-6781-A* A 3.8L 1982-83 RTV 4.1L 1977-80 D0DZ-6781-B A 4.2 1980-82 D9AZ-6781-A A 4.9L 1977-83 E3TZ-6781-B* A 5.0L 1977-83 D9AZ-6781-A A 5.8L (W) 1977-83 D0AZ-6781-C* A 5.8L (M), 6.6L 1977-82 D0AZ-6781-D A 6.1L 1983 D9HZ-6781-A AQ 7.0L 1982 D9HZ-6781-A AQ 7.5L 1977-81 E0UZ-6781-A A *High Swell Material. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Oil Pan Gasket, Engine > Component Information > Technical Service Bulletins > Seals For Rocker Cover, Oil Pan, and Crankshaft > Page 783 ARTICLE SUPERSEDED:83-5-7WARRANTY STATUS:"INFORMATION ONLY" CRANKSHAFT SEAL Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Cover Gasket > Component Information > Technical Service Bulletins > Seals For Rocker Cover, Oil Pan, and Crankshaft Valve Cover Gasket: Technical Service Bulletins Seals For Rocker Cover, Oil Pan, and Crankshaft Article No. 83-13-6 LEAKS - OIL - CURRENT SEALS FOR ROCKER COVER, OIL PAN, AND CRANKSHAFT FORD 1983 AND PRIOR LINCOLN-MERCURY 1983 AND PRIOR LIGHT TRUCKS 1983 AND PRIOR MEDIUM/HEAVY TRUCKS 1983 AND PRIOR The following charts outline current gasket identification for rocker cover, oil pan, and crankshaft seal applications to provide the most effective sealing. Those rocker cover and oil pan applications that use "High Swell Material" are shown by an asterisk (* ). ROCKER COVER GASKETS Engine Year Part Number Class 1.6L 1981-83 E3FZ-6584-A* A 2.3L 1977-83 E2ZZ-6584-A A 3.3L 1977-83 E3BZ-6584-A* A 4.1L 1977-80 E3BZ-6584-A* A 3.8L 1982-83 RTV 1983 E3DZ-6584-A* A w/metal rocker cover 4.2L 1980-82 E3AZ-6584-A* A 4.9L 1977-83 E3TZ-6584-C* A 5.0L, 5.0L HO 1977-83 E3AZ-6584-A* A 5.8L (W) 1977-83 E3AZ-6584-A* A 5.8L (M) 1980-82 D00Z-6584-A A 6.6L 1973-79 D00Z-6584-A A 6.1L 1983 E3TZ-6584-E* A 7.0L 1980-82 E3TZ-6584-E* A 7.5L 1979-79 E3TZ-6584-E* A OIL PAN GASKETS Engine Year Part Number Class 1.6L 1981-83 E1FZ-6781-A A 2.3L 1977-83 E2ZZ-6781-A AM 3.3L 1977-83 D0DZ-6781-A* A 3.8L 1982-83 RTV 4.1L 1977-80 D0DZ-6781-B A 4.2 1980-82 D9AZ-6781-A A 4.9L 1977-83 E3TZ-6781-B* A 5.0L 1977-83 D9AZ-6781-A A 5.8L (W) 1977-83 D0AZ-6781-C* A 5.8L (M), 6.6L 1977-82 D0AZ-6781-D A 6.1L 1983 D9HZ-6781-A AQ 7.0L 1982 D9HZ-6781-A AQ 7.5L 1977-81 E0UZ-6781-A A *High Swell Material. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Cover Gasket > Component Information > Technical Service Bulletins > Seals For Rocker Cover, Oil Pan, and Crankshaft > Page 788 ARTICLE SUPERSEDED:83-5-7WARRANTY STATUS:"INFORMATION ONLY" CRANKSHAFT SEAL Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Switch <--> [Oil Pressure Sender] > Component Information > Locations Oil Pressure Switch: Locations LH Lower Front Of Engine Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair Timing Chain: Service and Repair Fig. 27 Valve timing alignment marks Fig. 32 Timing marks aligned for correct valve timing. 1982 V6-232 V6-232, V8-255, 302, 351, 400 & 460 After removing the cover as outlined previously, remove the crankshaft front oil slinger, if equipped. On V6-232 engines, remove camshaft thrust button and spring from end of camshaft. Crank the engine until the timing marks are aligned as shown in Figs. 31 and 32. Remove camshaft sprocket retaining bolt, washer and fuel pump eccentric. Slide sprockets and chain forward and remove them as an assembly. Reverse the order of the foregoing procedure to install the chain and sprockets, being sure the timing marks are properly aligned. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair Timing Cover: Service and Repair V8-255, 302 & 351W E-100-350 1. Drain cooling system and, on 1981-87 models, remove radiator. 2. On models equipped with A/C, remove A/C idler pulley and bracket and compressor drive belt. 3. On all models, remove upper radiator hose, then the fan and shroud as an assembly. 4. Raise and support vehicle. 5. Remove alternator drive belt, then disconnect lower radiator hose from water pump. 6. Remove fuel pump, then lower vehicle. 7. Remove bypass hose, then the power steering pump drive belt (if equipped). 8. Remove pulley and disconnect heater hose from water pump. 9. On models equipped with A/C, remove A/C compressor upper bracket and (if equipped), the power steering pump mount from compressor and water pump. 10. On all models, remove crankshaft pulley and vibration damper. 11. Remove timing case cover-to-oil pan attaching bolts, then the timing case cover and water pump as an assembly. 12. Reverse procedure to install. Apply RTV sealant to oil pan-to-cylinder block mating surface. V8-351M & 400 1. Drain cooling system and disconnect battery cables. 2. Remove fan shroud attaching bolts and slide shroud rearward. 3. Remove fan and fan spacer from water pump shaft. 4. On models equipped with A/C, remove A/C compressor drive belt lower idler pulley and compressor mount-to-water pump bracket. 5. On all models, remove alternator drive belt, power steering pump drive belt (if equipped) and water pump pulley. 6. Remove alternator bracket and power steering pump bracket (if equipped) from water pump and position aside. 7. Disconnect heater hose and lower radiator hose from water pump. 8. Remove crankshaft pulley, vibration damper and timing pointer. 9. Remove timing case cover-to-cylinder block attaching bolts, then the timing case cover and water pump as an assembly. 10. Reverse procedure to install. Apply suitable sealant to cylinder block and timing case cover gasket surfaces. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications SPECIFICATIONS Pressure .............................................................................................................................................. .............................................................. 6.0-8.0 PSI Volume .............................................................. ................................................................................................................................. 1 pint in 20 seconds NOTE: Measurements taken with engine idling. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 804 Fuel Pressure: Testing and Inspection PRESSURE TEST 1. Connect a suitable pressure gauge (0-15 PSI) to the carburetor end of the fuel line. WARNING: Use care to prevent combustion of spilled fuel. 2. Start the engine (it should be able to run for over 30 seconds on the fuel in the carburetor bowl) and read the pressure after 10 seconds. If pump pressure is too low or too high install a new fuel pump. Fuel Pump Pressure ............................................................................................................................ ................................................. 6.0-8.0 PSI 3. Reconnect fuel line at filter and install air cleaner. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications IDLE SPEED SPECIFICATIONS Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Curb Idle Speed Idle Speed: Adjustments Curb Idle Speed Identification CARBURETOR IDENTIFICATION 2150-2V, 2150A-2V Carburetor Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Curb Idle Speed > Page 810 Variable Venturi, 7200-VV Carburetor Type 2150-2V CURB IDLE SPEED ADJUSTMENT - Place the transmission in Neutral (manual) or Park (automatic). - Bring engine to normal operating temperature (upper radiator hose hot). - Place the transmission in the specified gear. See: Specifications Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Curb Idle Speed > Page 811 - Check curb idle rpm. Adjust to specification. See: Specifications - Place the transmission in Neutral (manual) or Park (automatic). Rev the engine momentarily. Place the transmission in specified position, and recheck curb idle rpm. Readjust if required. Type 7200-VV Carburetor CURB IDLE SPEED ADJUSTMENT - Place the transmission in Neutral (manual) or Park (automatic). - Bring the engine to normal operating temperature. - Disconnect purge hose on canister side of evaporator purge solenoid. Check to ensure that purge vacuum is present (solenoid has opened, will require a 3-5 minute wait after starting engine, followed by a short time at part throttle. Reconnect purge hose. - Disconnect and plug the vacuum hose to the Vacuum Operated Throttle Modulator (VOTM) kicker. - Place the transmission in specified position. See: Specifications With Automatic Transmission Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Curb Idle Speed > Page 812 With Manual Transmission - Check/adjust curb idle rpm. See: Specifications - Place the transmission in Neutral or Park. Rev the engine momentarily. Place the transmission in specified position and recheck curb idle rpm. Readjust if required. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Curb Idle Speed > Page 813 Idle Speed: Adjustments Fast Idle Speed Identification CARBURETOR IDENTIFICATION 2150-2V, 2150A-2V Carburetor Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Curb Idle Speed > Page 814 Variable Venturi, 7200-VV Carburetor Type 2150-2V Carburetor FAST IDLE SPEED ADJUSTMENT - Place the transmission in Park (automatic) or Neutral (manual). - Bring the engine to normal operating temperature. - Disconnect the vacuum hose at the EGR valve and plug. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Curb Idle Speed > Page 815 - Place the fast idle adjustment mechanism on top step of fast idle cam. Check/adjust fast idle rpm to specification. See: Specifications - Recheck for repeatability. - Remove the plug from the EGR vacuum hose and reconnect. Type 7200-VV Carburetor FAST IDLE SPEED ADJUSTMENT - Place the transmission in Neutral (manual) or Park (automatic). - Bring the engine to normal operating temperature. - Disconnect purge hose on canister side of evaporator purge solenoid. Check to ensure that purge vacuum is present (solenoid has opened, will require a 3-5 minute wait after starting engine, followed by a short time at part throttle. Reconnect purge hose. Disconnect the vacuum hose at the EGR valve and plug. - Place the fast idle adjustment mechanism on the second step of the fast idle cam. - Check/adjust fast idle rpm to specification. Recheck for repeatability. See: Specifications - Remove the plug from the EGR vacuum hose and reconnect. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Technical Service Bulletins > Air Cleaner - Sealing Procedure Air Cleaner Housing: Technical Service Bulletins Air Cleaner - Sealing Procedure Article No. 83-25-21-S AIR CLEANER SEALING - 4.9L (1982-83 F-SERIES AND BRONCO ONLY) AND ALL UNITS WITH 5.0L, 5.8L OR 7.5L ENGINES. UNITS OPERATED IN DUSTY AND/OR OFF-ROAD CONDITIONS ARTICLE ALSO INCLUDES SEALING OF 7200VV CARBURETOR ON UNITS SO EQUIPPED LIGHT TRUCKS 1980-83 E, F AND BRONCO This is a re-write of TSB 83-25-21 (December 12, 1983). The air cleaner part numbers listed in the TSB are of insufficient detail and are therefore being deleted from the TSB. Due to the variety of different air cleaners used, part numbers have not been included in this TSB. See your normal parts listing for these part numbers. The subject vehicles operated in dusty/off-road conditions may experience an air cleaner sealing concern which could lead to engine oil consumption or, on 7200 VV carburetor equipped vehicles, a poor running condition. The following procedure should minimize these concerns. 1. Remove the air cleaner assembly from the engine and remove any loose debris from inside the tray. Replace the air cleaner assembly (9600) on all 1983 4.9L, 5.0L, 5.8L and, 7.5L equipped light trucks except the 1983 Econoline with the 4.9L engine. Due to the variety of different air cleaners used, part numbers have not been included in this TSB. See your normal parts listings for these part numbers. 2. Wipe the sealing surfaces clean on the tray and cover and inspect for any dents or damage that would prevent a good seal. Replace any damaged components. 3. Inspect the air cleaner to carburetor gasket for proper installation. If the gasket appears crimped or damaged, replace it with a new sticky-back gasket. Prior to replacing the gasket, clean the carburetor flange. Install the new gasket sticky side down and press all the gasket down to assure a tight bond. Gasket parts numbers: 4.9L - C8DZ-9654-A, 5.0L/5.8L/7.5L - D8ZZ-9654-A. FIGURE 24 4. For F-Series and Bronco only, relocate the zip tube inlet. a) Detach the zip tube inlet from the radiator support. b) Move the inlet to the top rear of the wheel wellhousing per Figure 24. c) Secure the zip tube to the top of the housing with a nylon tie-down strap. NOTE: At high temperatures, an octane ping may occur. If it persists, the zip tube must be reinstalled to the radiator support. 5. Replace the PCV filter. For 4.9L, 5.0L-2V, 5.8L-2V and 7.5L-4V engines replace the PCV filter in the air cleaner with an in-line filter. a. Remove and discard the crankcase breather cap to PCV filter hose (closure hose), PCV filter in the air cleaner, the adapter at the air cleaner and the adapter retaining clip. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Technical Service Bulletins > Air Cleaner - Sealing Procedure > Page 820 b. Drill a 5/16" hole in the side wall of the air cleaner approximately 12" to the rear of the existing crankcase closure hole for 5.0L and 5.8L and approximately 6" to the rear on 7.5L. (The 4.9L does not need a new hole). c. Install a 1/2" hose (E2AZ-6853-A) to the existing adaptor in the valve cover oil fill cap (2 pcs. 2-5/8" long for 4.9L, 18" long for 5.0L/5.8L, 12" long for 7.5L). d. At a convenient location, cut the hose and install an in-line filter E2AZ-6A768-A for 5.0L, 5.8L and 7.5L. On the 4.9L, install the filter between the 2-5/8" long pieces installed in (c.). NOTE: Install the filter with the wire mesh toward the oil fill cap. The mesh can be seen by looking into the end of the filter assembly. e. Install an adapter E43Z-9E606-A in the air cleaner and attach using a retaining clip 383741-S. Center the adapter elbow in the new hole for 5.0L, 5.8L and 7.5L. Use the existing PCV filter (closure) pack hole for 4.9L. f. Cut the PCV filter (closure) hose to proper length and attach to the adapter. g. Plug the old hole in the tray with plug 377678-S for 5.0L, 5.8L and 7.5L only. FIGURE 25 6. For 5.0L and 5.8L engines with a 7200 VV carburetor, clean and seal the carburetor to prevent dirt migration through the choke rod and accelerator pump rod holes (Refer to Figure 25). a. Remove the carburetor from the vehicle. b. Without disassembling the carburetor, thoroughly clean with Ford Automatic Choke Cleaner or equivalent, all of the choke linkage and accelerator pump linkage on the top and sides of the carburetor. Pay particular attention to the top and bottom of the upper body casting around the choke and accelerator pump rods. Allow cleaner to evaporate or blow dry with shop air. c. Remove stepper motor, gasket, pintle and spring. Clean pintle and pintle cavity in main body casting thoroughly with Ford Automatic Choke Cleaner or equivalent. Do not re-install stepper motor at this time. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Technical Service Bulletins > Air Cleaner - Sealing Procedure > Page 821 FIGURE 24 d. Hold throttle lever in the wide-open throttle position to raise the accelerator pump rod. With a toothpick, or other sharp tool, apply any commercially available silicone RTV (such as Dow Corning "Silastic") to the top side of the upper body casting around the accelerator pump rod (Figure 24). Fill the hole completely around the rods from the top side only and release the throttle lever. e. With a rubber band, tie the throttle lever in closed-throttle position. Push fast idle cam to "off" position so that choke rod is fully raised. Fast idle cam should remain in "off" position. f. With a toothpick, apply silicone RTV to bottom side of upper body casting around the choke shaft rod. Fill the hole completely around the rod from the bottom side only. g. Install the spring, pintle, gasket, and stepper motor. h. Allow carburetor to stand at room temperature for 24 hours without disturbing silicone RTV. i. After 24-hour cure, remove rubber band from throttle lever, and open throttle to break (free) accelerator pump rod from silicone RTV. Bulk of RTV sealant should remain attached to upper body. j. Manually exercise choke linkage to break (free) choke rod from silicone RTV. Bulk of RTV sealant should remain attached to upper body. k. Re-install carburetor on vehicle. 7. Re-install and secure the air cleaner assembly as follows: a. Set the air cleaner tray assembly on the carburetor and check that nothing is preventing the tray seating securely and completely sealing the flange. b. Connect and secure the vacuum hoses. c. Install and seat a new heavy duty air cleaner element in the tray. Use E2TZ-9601-B (FA-732) for 4.9L and E0TZ-9601-A (FA-688) for 5.0L/5.8L. Use non-heavy duty element for 7.5L. NOTE: Use of incorrect element will allow dirt to be ingested and will damage the engine. d. Install the air cleaner cover and place the washer grommet rubber side down. Torque the wing nut hand tight (20 in.lbs.). Try to rotate the air cleaner assembly slightly. If it resists rotation, sealing to the carburetor is assured. e. Connect the crankcase filter hose securely. f. Install the heat riser tube. Connect the fresh air zip tube. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Technical Service Bulletins > Air Cleaner - Sealing Procedure > Page 822 Obtain an Authorized Modifications decal and list the date, dealer number and summary of alterations performed. Select a prominent place adjacent to the Vehicle Emission Control Information decal suitable for installing the Authorized Modifications decal. Clean the area, install the decal and cover it with a clear plastic decal shield. PART NUMBER PART NAME CLASS E2AZ-6A768-A PCV Filter C E2AZ-6853-A 1/2" PCV Hose C E43Z-9E606-A Adapter C E2TZ-9601-B Air Filter Element AM E0TZ-9601-A Air Filter Element AM C6TZ-9697-A Washer AM D8ZZ-9654-A Gasket A 377678-S Plug BR E3AZ-19562-A RTV Sealer A 390013-S36B Wing Nut S C8DZ-9654-A Gasket AM OTHER APPLICABLE ARTICLES: 83-25-21 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP9600C84 TIME: 6 cyl. - 0.5 Hr. 8 cyl. - 1.1 Hrs. DLR. CODING: Basic Part No. 9600 Code: 49 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel Filter - Replacement Information Fuel Filter: Technical Service Bulletins Fuel Filter - Replacement Information Article No. 85-6-10 FUEL FILTER REPLACEMENT INFORMATION - ALL WITH FUEL FILTERS ATTACHED TO THE CARBURETOR AND/OR FUEL LINE WITH A RUBBER HOSE FORD ALL 1985 AND PRIOR LINCOLN-MERCURY ALL 1985 AND PRIOR LIGHT TRUCK ALL 1985 AND PRIOR New fuel connector hoses and clamps should be used whenever a fuel filter is replaced. Due to possible deterioration of hose materials which may result if a vehicle is fueled with gasoline containing excessive levels of methanol or ethanol, a new fuel hose and clamps should be installed when the fuel filter is changed. DO NOT REUSE OLD HOSES OR CLAMPS. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Screw In Type Fuel Filter: Service and Repair Screw In Type REMOVAL 1. Remove the air cleaner assembly. 2. Loosen and remove the fuel tube from the filter. 3. Unscrew the filter from the carburetor. INSTALLATION 1. Apply one drop of thread sealer to the external thread of a new filter. Thread the filter into the carburetor inlet port. 2. Tighten the filter to 9.0-11.0 Nm (80-100 in-lbs). 3. Apply ESE-M2C39-E or equivalent oil to the fuel supply tube nut and flare , and hand start the nut into the fuel filter inlet approximately two threads. 4. Use an 11/16 inch wrench on the fuel filter to prevent the filter from rotating. Tighten the fuel filter to supply tube nut to 20-24 Nm (15-18 ft-lb). 5. Install air cleaner assembly. 6. Start the engine and check for fuel leaks. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Screw In Type > Page 829 Fuel Filter: Service and Repair Inlet Fitting Type REMOVAL - Remove the air cleaner. - Hold the fuel filter inlet hex nut with a backup wrench and unscrew the fuel line tube nut from the fuel filter inlet. WARNING: Use care to prevent combustion from fuel spillage. - Unscrew the fuel inlet fitting. Remove the gasket, filter and spring. - Discard the gasket and filter. INSTALLATION - Install the spring, new filter and gasket. - Hand start the fuel inlet fitting into the carburetor then, tighten to 10-24 Nm (90-125 lb-in). - Apply oil, ESE-M2C39-E or equivalent to the fuel tube nut threads and tube flare. - Hand start the fuel line tube nut into the fuel inlet fitting (approximately two threads). - Use a backup wrench on the fuel inlet fitting while tightening the fuel line tube nut to 20-24 Nm (15-18 lb-ft). - Start the engine and check for fuel leak. - Install the air cleaner. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > With EEC III Firing Order: Specifications With EEC III With EEC III The cylinders are numbered 1-4 on the Right side, starting with the front, and 5-8 on the left side, ending with the rear. Because of the unique dual level rotor used by the EEC-III Ignition system, the engine's firing order cannot be read off the top of Firing Order 1-3-7-2-6-5-4-8 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > With EEC III > Page 834 Firing Order: Specifications Without EEC III Without EEC III Firing Order 1-3-7-2-6-5-4-8 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Description and Operation Ignition Timing Connector: Description and Operation Fig. 20 Ignition Timing Vacuum Switch Below vacuum setting, this switch, Fig. 20, used on some vehicles, is open and signals the ignition module to retard spark timing. The switch is closed above the vacuum setting and the ignition module is in the non-retard spark timing mode. Calibration resistors inside the switch control the amount of retard. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Description and Operation > Page 839 Ignition Timing Connector: Testing and Inspection Ignition Timing Vacuum Switch Ignition Timing Vacuum Switch Test Chart 1. Disconnect switch from ignition module. 2. Connect suitable ohmmeter across switch terminals and compare resistance measured to ``less than'' values in the Ignition Timing vacuum Switch Test chart. 3. Apply vacuum to switch, using an outside vacuum source. Compare resistance now measured across switch terminals to ``greater than'' values in the Ignition Timing vacuum Switch Test chart. 4. Replace switch if resistance is not within specifications. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations > With Electronic Engine Controls (EEC) Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations > With Electronic Engine Controls (EEC) > Page 844 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Diagrams Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams Ignition Cable: Diagrams Spark Plug Wire Routing Ford F 250 5.8L Firing Order Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Page 851 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Page 852 Ignition Cable: Testing and Inspection Spark Plug Wire Resistance *** UPDATED BY TSB #85-9-33 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Advance Unit > Component Information > Specifications DISTRIBUTOR TIMING ADVANCE Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Advance Unit > Component Information > Description and Operation > Vacuum Spark Advance Mechanism Distributor Advance Unit: Description and Operation Vacuum Spark Advance Mechanism The vacuum spark control mechanism can provide spark advance if a single diaphragm assembly is used or spark advance and retard if a dual diaphragm assembly is used. The diaphragm assembly used depends on the engine calibration. Single Diaphragm Assembly SINGLE DIAPHRAGM ASSEMBLY The single diaphragm assembly, Fig. 11, also changes the armature to stator relationship to give spark advance. The stator assembly position is changed by means of vacuum being applied to the diaphragm assembly. Vacuum applied to the diaphragm assembly causes the diaphragm and attached diaphragm rod to move, compressing the advance spring, which controls the rate of advance. The movement of the diaphragm rod, which is attached to the stator assembly, makes the the stator assembly move with respect to the armature. This changes the initial armature to stator relationship set during initial timing, causing spark advance. The stator assembly is mounted on the lower plate assembly which with the diaphragm assembly, is attached to the distributor base. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Advance Unit > Component Information > Description and Operation > Vacuum Spark Advance Mechanism > Page 859 Dual Diaphragm Assembly DUAL DIAPHRAGM ASSEMBLY The dual diaphragm assembly, Fig. 12, obtains spark advance in the same manner as the single diaphragm assembly. In this case vacuum applied to the vacuum advance port causes the advance diaphragm and attached rod to move, otherwise the action is the same. Spark retard is done by applying vacuum to the vacuum retard port. This causes the retard diaphragm to move, compressing the retard spring, which controls the rate of spark retard. Compressing the retard spring allows the diaphragm rod stop to move due to the force applied by the advance spring pushing against it by means of the diaphragm rod. The result is the diaphragm rod moves causing the attached stator assembly to change position with respect to the armature. In this instance the direction of the stator assembly movement is opposite that occurring during vacuum advance, resulting in spark retard. NOTE: Any vacuum applied to the advance port overrides any spark retard caused by vacuum being applied to the retard port. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Advance Unit > Component Information > Description and Operation > Vacuum Spark Advance Mechanism > Page 860 Distributor Advance Unit: Description and Operation Centrifugal Spark Advance Mechanism Distributor - Exploded view The centrifugal advance mechanism varies the relationship of the armature to the stator assembly. The armature is mounted to the sleeve and plate assembly which rotates in relation to the distributor shaft. The rotation is a result of the centrifugal weights moving in response to engine RPM. The movement of the weights change the initial relationship of the armature to the stator assembly by rotating the sleeve and plate assembly ahead of its static position on the distributor shaft Fig. 1. This produces spark advance. The rate of movement of the weights is controlled by calibrated springs. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Advance Unit > Component Information > Description and Operation > Page 861 Distributor Advance Unit: Service and Repair 1. Remove distributor cap and rotor. 2. Disconnect vacuum lines, then remove snap ring that secures vacuum advance link to pickup assembly. 3. Remove vacuum advance attaching screws, then tilt unit downward to disconnect link. 4. Carefully remove unit from distributor. 5. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Retard Control > Component Information > Locations Distributor Retard Control: Locations Below Vacuum Switch Between No. 5 & No. 6 Spark Plugs Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Vacuum Control > Component Information > Description and Operation Distributor Vacuum Control: Description and Operation 3-Port Vacuum Regulator Vacuum Regulator (3 & 4 Port) Three port, Fig. 27, regulators and four port, Fig. 28, regulators are used to control the vacuum advance to the distributor. During engine idle conditions, the manifold vacuum signal is reduced to a constant output signal. Off idle, the output signal equals the spark port. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Vacuum Control > Component Information > Testing and Inspection > Distributor Modulator Valve Assembly Distributor Vacuum Control: Testing and Inspection Distributor Modulator Valve Assembly 1. Turn ignition key to ``ON'' and check resistance at solenoid terminals. 2. If solenoid resistance is not 51---108 ohms, replace solenoid. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Vacuum Control > Component Information > Testing and Inspection > Distributor Modulator Valve Assembly > Page 870 Distributor Vacuum Control: Testing and Inspection Vacuum Regulator Procedure 1. Disconnect vacuum line from distributor port and connect a vacuum gauge. 2. With engine at idle, the vacuum gauge reading should be within 1 inch Hg. vacuum of the calibration point. The calibration point of each valve can be identified according to color code as follows: Black, 6 inches Hg.; green, 7 inches Hg.; red, 8 inches Hg. 3. Replace valve if not within specifications. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > Ignition Rotor - Alignment Procedure Ignition Rotor: Technical Service Bulletins Ignition Rotor - Alignment Procedure Article No. 83-8-14 EEC III/DISTRIBUTOR - PROCEDURE FOR SETTING ROTOR ALIGNMENT 5.0L/5.8L EEC EQUIPPED LIGHT TRUCKS LIGHT TRUCKS 1981/83 BRONCO, F-SERIES AND ECONOLINE The following information and procedures are issued to clarify the proper setting of distributor rotor alignment on the subject vehicles. This reference publication supersedes all other printed material on subject. FIGURE 12 FIGURE 13 For 1981 through 1983 model year vehicles, EEC distributors used on the EEC Systems had the "second generation" rotor (Figure 12). The 1983 model 5.0L EEC equipped Light Truck employs a conventional rotor (Figure 13). PROCEDURE FOR ROTOR ALIGNMENT: 1. Remove the distributor cap and wires and position them to one side. 2. Remove the rotor. 3. To check rotor alignment: a. Rotate the engine until the No. 1 piston is on the compression stroke. NOTE: Verification of being on the compression stroke is essential to correct rotor alignment. If the piston is on the exhaust stroke, the rotor can be misaligned by 180~. b. Slowly rotate the engine until the alignment tool can be installed. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > Ignition Rotor - Alignment Procedure > Page 875 FIGURE 14 c. The T79P-12200-A tool mounts between the slot on the sleeve and the slot (cut out) on the adapter (Figure 14). d. Read the timing mark on the damper indicated by the timing pointer. e. If the timing mark is specification, TDC +/- 4~, the rotor alignment is satisfactory. The alignment tool can be removed. TO ADJUST ROTOR ALIGNMENT: 1. Remove the distributor cap by loosening the two spring clips holding the cap of the distributor adapter. Remove rotor. 2. Rotate engine until No. 1 piston is on the compression stroke. (See Step 3a above). 3. Slowly rotate the engine until the timing pointer is aligned with the specified timing mark. (TDC +/- 4~). 4. Loosen the two sleeve assembly adjustment screws and rotate the sleeve until the alignment tool T79PFIGURE 14 12200-A fits into the alignment slots on the sleeve and the adapter (Figure 14). 5. Tighten the adjustment screw to 2.8-3.9 N-m (25-30 lb.in.). Remove alignment tool. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > Ignition Rotor - Alignment Procedure > Page 876 FIGURE 13 6. If the vehicle is a 1983 model equipped with a 5.0L engine, coat the rotor with silicone grease as shown in Figure 13. 7. Reinstall distributor cap and rotor making sure wires are firmly seated in the distributor cap terminal housings and on the spark plugs. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Plate W/ Pick-up Sensor > Component Information > Service and Repair Distributor Plate W/ Pick-up Sensor: Service and Repair 1. Remove distributor cap and rotor. 2. Remove vacuum advance unit and magnetic pickup assembly. 3. Remove attaching screws and lift base plate from distributor. 4. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Vacuum Spark Delay Valve > Component Information > Description and Operation Vacuum Spark Delay Valve: Description and Operation Fig.25 - Spark Delay Valve This unit is used in conjunction with some of the other Ford systems. Its purpose is to further reduce emissions by delaying the spark advance during rapid acceleration and by cutting off advance immediately upon deceleration. Fig. 25. This plastic disc-shaped valve is installed in the carburetor vacuum line at the distributor advance diaphragm. It is a one way valve and will not operate if installed backwards. The black side of the valve must be toward the carburetor. This valve cannot be repaired. NOTE: On all systems which employ the dual diaphragm distributor the line which has high vacuum at idle (normal operating temperature) is connected to the secondary (retard) side of the distributor vacuum advance unit. This is the connection closest to the distributor cap. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Vacuum Spark Delay Valve > Component Information > Description and Operation > Page 883 Vacuum Spark Delay Valve: Testing and Inspection Fig.36 - SDV Valve Color Coding Fig.37 - Spark Delay Valve (SDV) Specifications Chart Refer to Figs. 36 & 37 for number value by color code. NOTE: To perform the following procedure, an external vacuum source capable of maintaining a minimum constant 10 inches Hg. is required. Mono Delay Valve 1. Set external vacuum source to 10 inches Hg. and connect black side of delay valve to vacuum source. 2. Connect a vacuum gauge with a 24 inch hose to colored side of delay valve. 3. Apply 10 inches Hg. vacuum and observe time in seconds for gauge to read 0-8 inches Hg. The minimum and maximum time for gauge to read 8 inches Hg. should be as shown in Fig. 37. Dual Delay Valve 1. Set external vacuum source to 10 inches Hg. and connect vacuum gauge with a 24 inch hose to DIST nipple of delay valve. 2. Connect black side of delay valve and CARB nipple of delay valve to vacuum source. NOTE: Avoid applying vacuum to CARB nipple while applying vacuum to black side of valve. 3. Apply 10 inches Hg. of vacuum and observe time in seconds for gauge to read from 0-8 inches Hg. The minimum and maximum time for gauge to read 8 inches Hg. should be as shown in Fig. 37. Retard Delay Valve 1. Set external vacuum source to 10 inches Hg. and connect colored side of delay valve to vacuum source. 2. Connect a vacuum gauge with a 24 inch hose to white side of delay valve. 3. Apply 10 inches Hg. of vacuum and observe time in seconds for gauge to read from 0-8 inches Hg. The minimum and maximum time for gauge to read 8 inches Hg. should be as shown in Fig. 37. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications SPARK PLUGS Gap ...................................................................................................................................................... ............................................................ 0.044 in Torque ...................................................................... ............................................................................................................. 14-20 Nm (10-15 ft-lbs) Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 887 Spark Plug: Service and Repair REMOVAL - Remove the wire from each spark plug by grasping the molded boot with tool T74P-6666-A or equivalent. Twist the boot until it loosens and then pull it off the spark plug. Do not pull on the wire, as the connection may become damaged. - Any wire damaged must be replaced. Each original spark plug wire is numbered for the cylinder to which it is designated. If wires are not numbered, each wire should be numbered as to the plug from which it was removed. - Clean the area around each spark plug port with compressed air. - Using the proper size spark plug socket remove the spark plugs. INSTALLATION Check the gap on each new spark plug and set to specification. See: Specifications Cylinder Numbering And Distributor Location - Install each spark plug and tighten to 14-20 Nm (10-15 ft-lbs). - Coat the inside of each spark plug boot with silicone dielectric compound. Connect each spark plug wire to the plug from which it was removed. Be sure each wire is fully depressed on each plug and molded boot is firmly in place. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis Compression Check: Testing and Inspection COMPRESSION TEST 1. Ensure oil in crankcase is of the correct viscosity and at proper level and battery is properly charged. Operate vehicle until engine is at normal operating temperature. Turn OFF ignition switch, then remove all spark plugs. 2. Set throttle plates (and choke plates, if equipped) in wide-open position. 3. Install a compression gauge such as Rotunda Compression Tester 059-00009 or equivalent in No. 1 cylinder. 4. Install an auxiliary starter switch in starting circuit. With ignition switch in the OFF position, and using auxiliary starter switch, crank engine at least five compression strokes and record highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat test on each cylinder cranking the engine approximately the same number of compression strokes. TEST CONCLUSION 1. The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest. 2. If one or more cylinders read low, squirt approximately one tablespoon of heavy SAE 50 weight or equivalent engine oil on top of the pistons in the low reading cylinders. Repeat compression pressure check on these cylinders. a. If compression improves considerably, piston rings are at fault. b. If compression does not improve, valves are sticking or seating poorly. c. If two adjacent cylinders indicate low compression pressures and squirting oil on pistons does not increase compression, cause may be a cylinder head gasket leak between cylinders. Engine oil and/or coolant in cylinders could result from this problem. Compression Pressure Limit Chart NOTE: Refer to the compression pressure limit chart for pressure specifications. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications ENGINE YEAR CLEARANCE V6-232 82-83 .088-.189 V8-255 81-82 .123-.173 6-300 80-87 .125-.175 V8-302 80-87 .096-.165 V8-351M 80-81 .125 V8-351W 80-87 .123-.173 V8-400 80-82 .175 V8-460 80-87 .100-.150 On engines with hydraulic lifters, clearance specified is at valve stem tip with lifter collapsed. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 894 Valve Clearance: Locations FRONT TO REAR 6-300 E-I-E-I-E-I-E-I-E-I-E-I V6-232 Right I-E-I-E-I-E V6-232 Left E-I-E-I-E-I V8-255, 302 Left Bank E-I-E-I-E-I-E-I V8-255, 302 Right Bank I-E-I-E-I-E-I-E V8-351, 400 Right Bank I-E-I-E-I-E-I-E V8-351, 400 Left Bank E-I-E-I-E-I-E-I V8-460 Left Bank E-I-E-I-E-I-E-I V8-460 Right Bank I-E-I-E-I-E-I-E Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 895 Valve Clearance: Adjustments Fig. 21 Compressing valve lifter with tool to check clearance on engines with hydraulic valve lifters V8 ENGINES To provide a means to compensate for dimensional changes in the valve train and provide for valve adjustment, .060 inch shorter or longer pushrods are available. If the valve clearance is less than the minimum, the .060 inch shorter pushrod should be used. If the clearance is more than the maximum, the longer pushrod should be used. To check the valve clearance, proceed as follows: 1. Mark crankshaft pulley at three locations, with No. 1 location at TDC timing mark (end of compression stroke), location No. 2 one full turn (360°) clockwise from TDC and No. 3 location one quarter turn clockwise (90°) from position No. 2. 2. Turn crankshaft to number 1 location, then compress valve lifter using tool T71P-6513-A or equivalent, Fig. 21, and check the clearance on the following valves: V8-255, 302, 460 No. 1 Intake No. 1 Exhaust No. 7 Intake No. 5 Exhaust No. 8 Intake No. 4 Exhaust V8-351 & 400 No. 1 Intake No. 1 Exhaust No. 4 Intake No. 3 Exhaust No. 8 Intake No. 7 Exhaust 3. Turn crankshaft to number 2 location, then compress valve lifter using tool T71P-6513-A or equivalent, Fig. 21, and check the clearance on the following valves: V8-255, 302, 460 No. 5 Intake No. 2 Exhaust No. 4 Intake No. 6 Exhaust V8-351 & 400 No. 3 Intake No. 2 Exhaust No. 7 Intake No. 6 Exhaust 4. Turn crankshaft to number 3 location, then compress valve lifter using tool T71P-6513-A or equivalent, Fig. 21, and check the clearance on the following valves: V8-255, 302, 460 No. 2 Intake No. 7 Exhaust No. 3 Intake No. 3 Exhaust No. 6 Intake No. 8 Exhaust V8-351 & 400 No. 2 Intake No. 4 Exhaust No. 5 Intake No. 5 Exhaust No. 6 Intake No. 8 Exhaust Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair Water Pump: Service and Repair ]All water pumps have a sealed bearing integral with the water pump shaft. The bearing requires no lubrication. A bleed hole in the pump housing allows water that may leak past the seal to be thrown out by the slinger. This is not a lubrication hole. If the pump is damaged and requires repair, replace it with a new pump or a rebuilt one. V8-255, 302 & 351W E-100-350 1. Remove air cleaner and intake duct assembly, including crankcase ventilation hose. 2. Drain cooling system, then remove radiator. 3. Remove drive belts, fan, spacer and water pump pulley. 4. Disconnect heater and bypass hoses from water pump. 5. Remove water pump attaching bolts and the water pump. 6. Reverse procedure to install. V8-351M & 400 1. Disconnect battery ground cable, then drain cooling system. 2. Remove fan shroud attaching bolts and slide shroud rearward. 3. Remove fan and fan spacer. 4. On models equipped with A/C, remove A/C compressor drive belt, lower idler pulley and compressor mount-to-water pump bracket. 5. On all models, remove alternator drive belt and power steering pump drive belt (if equipped). 6. Remove water pump pulley, then the alternator bracket from water pump. 7. On models equipped with power steering, unfasten steering pump bracket from water pump and position aside. 8. On all models, disconnect lower radiator hose and heater hose from water pump. 9. Remove water pump attaching bolts and the water pump. 10. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recycled Engine Coolant - Service Tips Coolant: Technical Service Bulletins Recycled Engine Coolant - Service Tips Article No. 95-18-2 09/11/95 ^ COOLANT - USE OF RECYCLED ENGINE, COOLANT - SERVICE TIP ^ COOLING SYSTEM - USE OF RECYCLED ENGINE, COOLANT - SERVICE TIP FORD: 1980 and after CROWN VICTORIA, MUSTANG, THUNDERBIRD 1981 and after ESCORT 1982-88 EXP 1984-94 TEMPO 1986 and after TAURUS 1988-93 FESTIVA 1989 and after PROBE 1994 and after ASPIRE 1995 and after CONTOUR LINCOLN-MERCURY: 1980 and after CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1981-86 CAPRI 1981-87 LYNX 1984-92 MARK VII 1984-94 TOPAZ 1986 and after SABLE 1987-89 TRACER 1991-94 CAPRI 1991 and after TRACER 1993 and after MARK VIII 1995 and after MYSTIQUE MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1980 and after F-150-350 SERIES 1981 and after ECONOLINE 1982 and after BRONCO 1983 and after RANGER 1984-90 BRONCO II 1986 and after AEROSTAR 1988 and after F SUPER DUTY 1991 and after EXPLORER 1993 and after VILLAGER 1995 and after WINDSTAR This TSB is being republished in its entirety to include warranty information when using recycled coolant ISSUE: Ford Motor Company authorizes the use of recycled engine coolant that, when properly processed and reinhibited, meets Ford specification ESE-M97B44-A. At this time, the Rotunda Coolant Recycler (181-00003) process is the only approved coolant recycling method available through Ford that is capable of producing recycled engine coolant that meets Ford specification ESE-M97B44-A. ACTION: Refer to the following Service Procedure for coolant processing and reinhibiting using Rotunda Coolant Recycler (181-00003). NOTE: WHILE TESTING SHOWS THAT RECYCLED ENGINE COOLANT CAN PROVIDE ACCEPTABLE PERFORMANCE, THE COOLANT PRODUCED FROM ROTUNDA EQUIPMENT IS INTENDED FOR USE WITHIN DEALERSHIPS ON WARRANTY AND CUSTOMER PAY REPAIRS ONLY AND NOT INTENDED FOR RETAIL SALE. THERE ARE REGULATORY, PACKAGING AND LABELING CONCERNS Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recycled Engine Coolant - Service Tips > Page 904 ASSOCIATED WITH THE RETAIL SALE OF CHEMICAL PRODUCTS. CAUTION: THE REINHIBITOR CHEMICALS PROVIDED WITH THIS EQUIPMENT ARE NOT APPROPRIATE FOR USE ON MEDIUM/HEAVY TRUCK APPLICATIONS. WARNING: ROTUNDA PREMIUM COOLANT REINHIBITORS # 1 AND # 2 HAVE BEEN SPECIFICALLY FORMULATED TO WORK WITH ROTUNDA COOLANT RECYCLER (181-00003). USE OF ANY OTHER CHEMICAL ADDITIVES WITH THIS SYSTEM WILL VOID ALL WARRANTIES FOR THE EQUIPMENT AND FOR THE FINAL COOLANT PRODUCT. SERVICE PROCEDURE DIRECTIONS FOR PROCESSING USED ENGINE COOLANT WITH ROTUNDA COOLANT RECYCLER 1. Close the drain valve on the unit. 2. Open the fill valve. 3. Pour used engine coolant into the funnel on the side of the unit. NOTE: MAXIMUM CAPACITY 15 25 GALLONS (95 L). 4. Insert the outlet hoses of the recycler into clean, properly labeled containers. One (1) container is for the outlet process water and the other container is for distilled ethylene glycol. 5. Push the "ON" switch on the front to start the operation. The unit will process 1 gallon (3.8 L) per hour of operation and will automatically shut off when cycle is complete. 6. Add reinhibitor following the directions in this article. 7. Open the drain valve to drain the residue from the distillation vessel. Dispose of residue in accordance with all local. state and federal regulations. ADDING REINHIBITOR CHEMICALS 1. Process the coolant according to the directions listed in this article 2. Thoroughly mix 4 fl oz (118 ml) of Reinhibitor # 1 to each gallon of distilled ethylene glycol. 3. Thoroughly mix 4 fl oz (118 ml) of Reinhibitor # 2 to each gallon of distilled ethylene glycol. 4. Mix well. 5. Check the pH level of the coolant. The pH level must be between 9 and 11. 6. Add enough water to the concentrated coolant to produce a 50/50 mixture of coolant and water. NOTE: THE CONCENTRATED COOLANT MUST BE MIXED WITH WATER TO MEET THE NECESSARY ENGINE FREEZE PROTECTION. 7. Check the coolant freeze point of the 50% coolant solution. Freeze point should be -34°F (-37°C). Consult the Rotunda Coolant Recycler Manual for more detailed operating instructions. Call 1-800-ROTUNDA, 8 AM to 8 PM EST, for inquiries regarding the Rotunda Coolant Recycler and to order the Reinhibitor (187-R0001). PART NUMBER PART NAME Rotunda # 187-R0001 Rotunda Premium Coolant Reinhibitor WARRANTY CLAIMS: Dealer can claim recycled engine coolant by Ford approved process via a warranty repair on an 1863 claim as follows: Part Number: RECCOOL (not a valid part number, but it is recognized on an 1863 claim). Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Recycled Engine Coolant - Service Tips > Page 905 Quantity: Indicate the number of QUARTS of recycled coolant used. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 95-16-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Less A/C System Capacity Note: E-100-150 exc. super cooling & E-250-350 with standard cooling, 20qts.; E-100-150 with super cooling & E-250-350 with heavy duty cooling, 21 qts.; E-250-350 with super cooling, 28 qts. With A/C System Capacity 21 qt (US) Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 908 Coolant: Fluid Type Specifications COOLING SYSTEM FLUID, PREMIUM Ford Part No. U.S.A (Except Oregon) ............................................................................................................................................................ E2FZ-19549-AA or -B Canada ............................................................................................................ .............................................................................................. CXC-8-B Oregon .................................. ............................................................................................................................................................. F5FZ-19549-CC Ford Specification ................................................................................................................................ ................................................... ESE-M97B44-A COOLING SYSTEM FLUSH Ford Part No. ....................................................................................................................................... ................................................... F1AZ-19A503-A Ford Specification ................................................. ..................................................................................................................................... ESR-M14P7-A Coolant Mixture with Water ................................................................................................................. ...................................................................... 50% Warning: Do not mix coolant types. Check the owners manual or refer to your local dealer for the correct coolant type. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications Radiator Cooling Fan Temperature Sensor / Switch: Specifications Switch Torque Switch Torque Cooling Fan Switch 8-18 ft.lb Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Testing and Inspection > Inspection Fan Blade: Testing and Inspection Inspection WARNING: Do not operate engine until fan has first been inspected for cracks and/or separations. If a fan blade is found to be bent or damaged in any way, do not attempt to repair or reuse damaged part. Proper balance is essential in fan assembly operation. Balance cannot be assured once a fan assembly has been found to be bent or damaged and failure may occur during operation, creating an extremely dangerous condition. Always replace damaged fan assembly. Place fan on flat surface with leading edge facing down. If there is a clearance between fan blade touching surface and opposite blade of more than .090 inch (2 mm), replace fan. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Testing and Inspection > Inspection > Page 917 Fan Blade: Testing and Inspection Looseness Lateral movement can be observed at the fan blade tip under various temperature conditions because of the type bearing used. This movement should not exceed 1/4 inch (6.5 mm) as measured at the fan tip. If this lateral movement does not exceed specifications, there is no cause for replacement. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Testing and Inspection > Fan Clutch Fluid Leak Fan Clutch: Testing and Inspection Fan Clutch Fluid Leak Small fluid leaks do not generally affect the operation of the unit. These leaks generally occur around the area of the bearing assembly, but if the leaks appear to be excessive, engine overheating may occur. Check for clutch and fan free-wheeling by attempting to rotate fan and clutch assembly by hand five times. If no drag is felt, replace clutch. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Testing and Inspection > Fan Clutch Fluid Leak > Page 922 Fan Clutch: Testing and Inspection Fan Clutch Noise Fan clutch noise can sometimes be noticed when clutch is engaged for maximum cooling. Clutch noise is also noticeable within the first few minutes after starting engine while clutch is redistributing the silicone fluid back to its normal, disengaged operating condition after settling for long periods of time (over night). However, continuous fan noise or an excessive roar indicates the clutch assembly is locked-up due to internal failure. This condition can be checked by attempting to manually rotate fan. If fan cannot be rotated manually or there is a rough, abrasive feel as fan is rotated, the clutch should be replaced. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch > Component Information > Testing and Inspection > Fan Clutch Fluid Leak > Page 923 Fan Clutch: Testing and Inspection Fan Clutch Operational Test Do not operate the engine until the fan has been first checked for possible cracks and separations. Run engine at a fast idle speed (1000 RPM) until normal operating temperature is reached. This process can be done more quickly by blocking off the front of the radiator with cardboard. Regardless of temperatures, unit must be operated for at least five minutes immediately before being tested. Stop engine and using a glove or a cloth to protect the hand, immediately check the effort required to turn the fan. If considerable effort is required, it can be assumed that coupling is operating satisfactorily. If very little effort is required to turn the fan, it is an indication that the coupling is not operating properly and should be replaced. Bi-Metallic Coiled Spring Removal The clutch fan may be tested while vehicle is being driven. To check, disconnect the bimetal spring, Fig. 2, and rotate 90° counterclockwise. This disables the temperature-controlled, free-wheeling feature and the clutch performs like a conventional fan. If this cures the overheating condition, replace the clutch fan. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications TEMPERATURE SENSORS Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 928 Coolant Temperature Sensor/Switch (For Computer): Locations RH Side Of V8-302/5. Near Front Of RH Valve Cover Applicable to: 0L & V8-351/5.8L w/EEC Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 929 Coolant Temperature Sensor/Switch (For Computer): Description and Operation This sensor incorporates a thermistor in a brass housing with an integral wiring connector extending from the body. This sensor is installed in the heater outlet fitting of the intake manifold. The thermistor is a resistor whose resistance value is high at low temperatures and decreases as the temperature rises. The computer applies a voltage to the sensor and monitors the resultant voltage drop across the thermistor. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications Radiator Cooling Fan Temperature Sensor / Switch: Specifications Switch Torque Switch Torque Cooling Fan Switch 8-18 ft.lb Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Control Valve > Component Information > Locations Heater Control Valve: Locations Rear Of Engine Compartment Above RH Rear Side Of Engine Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Heater Core - Leakage Diagnostic Tips Heater Core: Technical Service Bulletins Heater Core - Leakage Diagnostic Tips Article No. 85-8-2 HEATER CORE - LEAK - DIAGNOSTIC TIPS FORD ALL LINCOLN-MERCURY ALL LIGHT TRUCK ALL Good heater cores are being returned through the parts return system coded as leaking. Complaints of leaking may be caused by an inadequate seal between the heater hose and the heater core tubes allowing coolant to follow the tube to the heater core, leak into the passenger compartment and appear as a leaking heater core. When diagnosing a suspect heater core leak, inspect the hose to heater core tube attachment to assure the connection is not leaking. If a leaking connection is found, correct the leak. If the connection appears not to be leaking, leak test the heater core before removing it from the vehicle using the following procedure: HEATER CORE LEAK TEST Pressure Test 1. Drain the coolant from the cooling system. 2. Disconnect the heater hoses from the heater core tubes. 3. Install a short piece of heater hose (approximately 4 inches long) on each heater core tube. Figure 1 4. Fill the heater core and hoses with water and install plug BT-7422-B and adapter BT-7422-A from Rotunda model 021-00012 or equivalent in the hose ends (Figure 1). Secure the hoses, plug and adapter with hose clamps. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Heater Core - Leakage Diagnostic Tips > Page 940 Figure 2 Figure 3 - TOOL 021-00012 WITH HEATER HOSE AND CLAMPS 5. Attach the pump and gauge assembly Rotunda model 021-00012 or equivalent to the adapter (Figure 2). Close the bleed valve at the base of the gauge and pump 30 psi of air pressure into the heater core (Figure 3). 6. Observe the pressure gauge for a minimum of three minutes. The pressure should not drop. 7. If the pressure does not drop, no leaks are indicated. 8. If the pressure drops, check the hose connections to the core tubes for leaks. If the hoses do not leak, remove the heater core from the vehicle and perform the bench test. Bench Test 1. Drain all coolant from the heater core. Figure 4 - HEATER CORE BENCH TEST 2. Connect the 4-inch test hoses with plug and adapter to the core tubes. Then connect the air pump and gauge assembly to the adapter (Figure 4). 3. Apply 30 psi of air pressure to the heater core with Rotunda model 021-00012 or equivalent, and submerge the core in water. 4. If a leak is observed, service or replace the heater core as necessary. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Heater Core - Leakage Diagnostic Tips > Page 941 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 942 Heater Core: Service and Repair Less Air Conditioning Fig. 11 Heater core replacement. E-100---350 less air conditioning 1. Disconnect battery ground cable. On models equipped with dual batteries, disconnect both negative cables. Remove RH battery from vehicle. 2. Drain cooling system. 3. Disconnect resistor electrical connector, then the blower motor lead wire from wiring harness. 4. Remove ground wire attaching screw from dash. 5. Disconnect hoses from heater core, then remove plastic wrap securing hoses to heater assembly. 6. Remove 5 heater assembly attaching screws from passenger compartment, then lift heater assembly out of engine compartment. 7. Remove seal and retainer from front of heater core case, then slide core and seal out of case. 8. Reverse procedure to install. W/Air Conditioning Fig. 12 Heater core replacement. E-100---350 w/air conditioning 1. Disconnect battery ground cable. On models equipped with dual batteries, disconnect both negative cables. Remove RH battery from vehicle. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 943 2. Disconnect electrical connector from resistor on front of air conditioner blower scroll cover. 3. Disconnect vacuum hose from outside recirculated door vacuum motor. 4. Remove air conditioner blower cover attaching screws and the cover. 5. Remove outside-recirculated door shaft push nut and washer. 6. Remove control cable attaching screw and slide cable over bracket. 7. Remove cable clip or wire loop from blend door shaft. 8. Remove 9 air conditioner blower motor housing attaching screws and the housing. 9. Remove 3 blend door housing attaching screws and the housing. 10. Drain cooling system, then disconnect hoses from heater core. 11. Remove 2 heater core retaining bracket attaching screws and the bracket. 12. Remove heater core and seal assembly. 13. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Dash Gauge Test Temperature Gauge: Testing and Inspection Dash Gauge Test Gauge failures are often caused by defective wiring or grounds. The first step in locating trouble should be a thorough inspection of all wiring, terminals and printed circuits. If wiring is secured by clamps, check to see whether the insulation has been severed, thereby grounding the wire. In the case of a fuel gauge installation, rust may cause failure by corrosion at the ground connection of the tank unit. The Constant Voltage Regulator (CVR) type indicator is a bimetal-resistance type system consisting of an Instrument Voltage Regulator (IVR), an indicator gauge, and a variable resistance sending unit. Current to the system is applied to the gauge terminals by the IVR, which maintains an average-pulsating value of 5 volts. The indicator gauge consists of a pointer which is attached to a wire-wound bimetal strip. Current passing through the coil heats the bimetal strip, causing the pointer to move. As more current passes through the coil, heat increases, moving the pointer farther. The circuit is completed through a sending unit which contains a variable resistor. When resistance is high, less current is allowed to pass through the gauge, and the pointer moves very little. As resistance decreases due to changing conditions in system being monitored, more current passes through gauge coil, causing pointer to move farther. Do not apply battery voltage to system or ground output terminals of IVR, as damage to system components or wiring circuits may result. DASH GAUGE TEST 1. Disconnect battery ground cable and remove gauge from vehicle. 2. Connect ohmmeter between gauge terminals and read coil winding resistance. 3. An upward movement of ohmmeter needle from 10 ohms to 14 ohms is normal, as test current of ohmmeter causes a temperature rise in gauge coil windings. 4. If ohmmeter reads below 10 ohms or above 14 ohms, gauge is defective. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Dash Gauge Test > Page 949 Temperature Gauge: Testing and Inspection Electrical Temperature Gauges This temperature indicating system consists of a sending unit, located on the cylinder head, electrical temperature gauge and an instrument voltage regulator. As engine temperature increases or decreases, the resistance of the sending unit changes, in turn controlling current flow to the gauge. When engine temperature is low, the resistance of the sending unit is high, restricting current flow to the gauge, in turn indicating low engine temperature. As engine temperature increases, the resistance of the ending unit decreases, permitting an increased current flow to the gauge, resulting in an increased temperature reading. TROUBLESHOOTING A special tester is required to diagnose this type gauge. Follow instructions included with the tester. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Testing and Inspection Temperature Warning Lamp/Indicator: Testing and Inspection A bimetal temperature switch located in the cylinder head control the operation of a temperature indicator light with a red lens. If the engine cooling system is not functioning properly and coolant temperature exceeds a predetermined value, the warning light will illuminate. TROUBLESHOOTING If the red light is not lit when the engine is being cranked, check for a burned out bulb, an open in the light circuit, or a defective ignition switch. If the red light is lit when the engine is running, check the wiring between light and switch for a ground, defective temperature switch, or overheated cooling system. As a test circuit to check whether the red bulb is functioning properly, a wire which is connected to the ground terminal of the ignition switch is tapped into its circuit. When the ignition is in the ``Start'' (engine cranking) position, the ground terminal is grounded inside the switch and the red bulb will be lit. When the engine is started and the ignition switch is in the ``On'' position, the test circuit is opened and the bulb is then controlled by the temperature switch. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Specifications Radiator Cap: Specifications Release Pressure 13 psi Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications TEMPERATURE SENSORS Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 961 Coolant Temperature Sensor/Switch (For Computer): Locations RH Side Of V8-302/5. Near Front Of RH Valve Cover Applicable to: 0L & V8-351/5.8L w/EEC Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 962 Coolant Temperature Sensor/Switch (For Computer): Description and Operation This sensor incorporates a thermistor in a brass housing with an integral wiring connector extending from the body. This sensor is installed in the heater outlet fitting of the intake manifold. The thermistor is a resistor whose resistance value is high at low temperatures and decreases as the temperature rises. The computer applies a voltage to the sensor and monitors the resultant voltage drop across the thermistor. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Radiator Cooling Fan Temperature Sensor / Switch > Component Information > Specifications Radiator Cooling Fan Temperature Sensor / Switch: Specifications Switch Torque Switch Torque Cooling Fan Switch 8-18 ft.lb Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Dash Gauge Test Temperature Gauge: Testing and Inspection Dash Gauge Test Gauge failures are often caused by defective wiring or grounds. The first step in locating trouble should be a thorough inspection of all wiring, terminals and printed circuits. If wiring is secured by clamps, check to see whether the insulation has been severed, thereby grounding the wire. In the case of a fuel gauge installation, rust may cause failure by corrosion at the ground connection of the tank unit. The Constant Voltage Regulator (CVR) type indicator is a bimetal-resistance type system consisting of an Instrument Voltage Regulator (IVR), an indicator gauge, and a variable resistance sending unit. Current to the system is applied to the gauge terminals by the IVR, which maintains an average-pulsating value of 5 volts. The indicator gauge consists of a pointer which is attached to a wire-wound bimetal strip. Current passing through the coil heats the bimetal strip, causing the pointer to move. As more current passes through the coil, heat increases, moving the pointer farther. The circuit is completed through a sending unit which contains a variable resistor. When resistance is high, less current is allowed to pass through the gauge, and the pointer moves very little. As resistance decreases due to changing conditions in system being monitored, more current passes through gauge coil, causing pointer to move farther. Do not apply battery voltage to system or ground output terminals of IVR, as damage to system components or wiring circuits may result. DASH GAUGE TEST 1. Disconnect battery ground cable and remove gauge from vehicle. 2. Connect ohmmeter between gauge terminals and read coil winding resistance. 3. An upward movement of ohmmeter needle from 10 ohms to 14 ohms is normal, as test current of ohmmeter causes a temperature rise in gauge coil windings. 4. If ohmmeter reads below 10 ohms or above 14 ohms, gauge is defective. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Dash Gauge Test > Page 970 Temperature Gauge: Testing and Inspection Electrical Temperature Gauges This temperature indicating system consists of a sending unit, located on the cylinder head, electrical temperature gauge and an instrument voltage regulator. As engine temperature increases or decreases, the resistance of the sending unit changes, in turn controlling current flow to the gauge. When engine temperature is low, the resistance of the sending unit is high, restricting current flow to the gauge, in turn indicating low engine temperature. As engine temperature increases, the resistance of the ending unit decreases, permitting an increased current flow to the gauge, resulting in an increased temperature reading. TROUBLESHOOTING A special tester is required to diagnose this type gauge. Follow instructions included with the tester. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Testing and Inspection Temperature Warning Lamp/Indicator: Testing and Inspection A bimetal temperature switch located in the cylinder head control the operation of a temperature indicator light with a red lens. If the engine cooling system is not functioning properly and coolant temperature exceeds a predetermined value, the warning light will illuminate. TROUBLESHOOTING If the red light is not lit when the engine is being cranked, check for a burned out bulb, an open in the light circuit, or a defective ignition switch. If the red light is lit when the engine is running, check the wiring between light and switch for a ground, defective temperature switch, or overheated cooling system. As a test circuit to check whether the red bulb is functioning properly, a wire which is connected to the ground terminal of the ignition switch is tapped into its circuit. When the ignition is in the ``Start'' (engine cranking) position, the ground terminal is grounded inside the switch and the red bulb will be lit. When the engine is started and the ignition switch is in the ``On'' position, the test circuit is opened and the bulb is then controlled by the temperature switch. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair Water Pump: Service and Repair ]All water pumps have a sealed bearing integral with the water pump shaft. The bearing requires no lubrication. A bleed hole in the pump housing allows water that may leak past the seal to be thrown out by the slinger. This is not a lubrication hole. If the pump is damaged and requires repair, replace it with a new pump or a rebuilt one. V8-255, 302 & 351W E-100-350 1. Remove air cleaner and intake duct assembly, including crankcase ventilation hose. 2. Drain cooling system, then remove radiator. 3. Remove drive belts, fan, spacer and water pump pulley. 4. Disconnect heater and bypass hoses from water pump. 5. Remove water pump attaching bolts and the water pump. 6. Reverse procedure to install. V8-351M & 400 1. Disconnect battery ground cable, then drain cooling system. 2. Remove fan shroud attaching bolts and slide shroud rearward. 3. Remove fan and fan spacer. 4. On models equipped with A/C, remove A/C compressor drive belt, lower idler pulley and compressor mount-to-water pump bracket. 5. On all models, remove alternator drive belt and power steering pump drive belt (if equipped). 6. Remove water pump pulley, then the alternator bracket from water pump. 7. On models equipped with power steering, unfasten steering pump bracket from water pump and position aside. 8. On all models, disconnect lower radiator hose and heater hose from water pump. 9. Remove water pump attaching bolts and the water pump. 10. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Dual Catalytic Converter Catalytic Converter: Description and Operation Dual Catalytic Converter Fig. 17 Dual catalytic converter This converter consists of two catalytic converters in one shell, with a mixing chamber in between the two, Fig. 17. Each converter is composed of a ceramic ``honey comb'' coated with a rhodium/platinum catalyst designed to control oxides of nitrogen (NOx), unburned hydrocarbons (HC) and carbon monoxide (CO), and is therefore called a ``three way catalyst'' (TWC). The rear converter is coated with platinum catalyst and is called a ``conventional'' oxidation catalyst'' (COC) converter. The platinum catalyst is also called a ``two way catalyst'' since it only acts on two of the major pollutants, HC and CO. The TWC converter acts on the exhaust gases from the engine. As the gases flow from the TWC to the COC converter, they mix with air from the thermactor pump injected into the mixing chamber or ``mid-bed''. This air is required for proper oxidation of HC and CO in the COC converter. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Dual Catalytic Converter > Page 982 Catalytic Converter: Description and Operation General Description Fig.8 - Catalytic Converter With Single Substrate Catalyst Fig.9 - Catalytic Converter With Dual Substrate Catalyst The catalytic converter is an emission control device added to the exhaust system to effectively reduce the levels of carbon monoxide (CO), hydrocarbons (HC), and in some cases oxides of nitrogen (NOx), entering the atmosphere. The converter permits a faster chemical reaction to take place and although it enters into the chemical reaction, it remains unchanged, ready to repeat the process. The catalyst in these converters is structured in the form of a honeycomb monolithic composition, Figs. 8 and 9. The catalyst consists of a porous substrate of an inert material, coated with platinum and other noble metals (the catalytically active materials). NOTE: Phase II Catalytic Converters or Dual Catalytic Converters which also control the NOx emissions, are used on some 1978-82 vehicles. During engine operation, all of the exhaust gases flow through the converter where a chemical change takes place. This change causes the temperature inside the converter to be higher than the temperature of the exhaust gases when they leave the engine. Due to this increase in heat, the converter is insulated so that its outside temperature is about the same temperature as the muffler. However, due to its solid mass, the converter remains hot much longer than the muffler. The body of the catalytic converter is made of stainless steel designed to last the life of the vehicle. Excessive heat can bulge or distort the converter. Since excessive heat built up is not the fault of the converter, the carburetion or ignition system should be checked whenever a converter is damaged by overheating. Although all vehicles with catalytic converter must use unleaded fuel, small amounts of leaded fuel can be used in case of an emergency. To prevent adding leaded fuel, the fuel tank filler nozzle has a built-in restrictor. Heat shields are used on some vehicles to protect chassis components, passenger compartment, and other areas from heat damage that may be caused by the catalytic converter. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 983 Catalytic Converter: Testing and Inspection Blocked or restricted exhaust system usually results in lack of power or popping through the intake system. Verify that this condition is not caused by ignition timing problems, then proceed with diagnosis. Catalyst and Exhaust Systems Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Description and Operation > Page 984 Catalyst and Exhaust Systems Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications Exhaust Manifold: Specifications Exhaust Manifold 18-24 ft.lb Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Specifications > Page 988 Exhaust Manifold: Service and Repair V8-255, 302 & 351W 1. Disconnect battery ground cable. 2. Remove air cleaner and intake duct assembly including crankcase ventilation hose. 3. Remove bolts attaching air cleaner inlet duct, if equipped. 4. Disconnect exhaust pipes at manifolds. 5. Remove exhaust manifold heat shields with attaching bolts and flat washers, if equipped. 6. Remove oil dipstick tube assembly, speed control bracket and exhaust heat control valve from left side exhaust manifold, if equipped, then remove exhaust manifold. 7. Reverse procedure to install, torquing attaching bolts to specifications from centermost bolts outward. V8-351M & 400 1. Disconnect battery ground cable. 2. When removing right side manifold, remove air cleaner, intake duct and heat shield. 3. When removing left side manifold, remove oil filter. 4. On 1980-82 models, remove oil dipstick and tube assembly and speed control bracket from left side exhaust manifold, if equipped. 5. On vehicles equipped with column selector and automatic transmission, disconnect selector lever cross shaft. 6. On all models, disconnect exhaust pipe at manifold and remove spark plug heat shields. 7. Remove exhaust manifold attaching bolts and the exhaust manifold. 8. Reverse procedure to install, torquing attaching bolts to specifications from center most bolts outward. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Technical Service Bulletins > Muffler - Unnecessary Replacement Muffler: Technical Service Bulletins Muffler - Unnecessary Replacement Article No. 83-11-11 EXHAUST - MUFFLER - POWER LOW - UNNECESSARY MUFFLER REPLACEMENT LIGHT TRUCKS 1982 AND LATER LIGHT TRUCKS Mufflers are being replaced on leaded fuel vehicles in an effort to resolve concerns of "lack of power" or poor performance", apparently in the belief that a plugged muffler is the cause. Although plugging with lead deposits was possible on certain models prior to the 1982 Model Year, muffler modifications incorporated on 1982 and later models make this an unlikely cause of the concern. Thus, replacing mufflers on the newer model vehicles normally will not satisfy the customer. Prior to replacing any muffler believed to be restricted, a vacuum check as described in Section 26-01 of the Light Truck Shop Manual should be performed. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations Engine Control Module: Locations LH Rear Of Engine Compartment LH Fender Apron Near Ignition Module Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 999 Engine Control Module: Description and Operation Fig. 7 Processor & calibration assembly The Electronic Control Assembly (ECA), Fig. 7, is the brain of the system. It is a solid state pre-programmed micro-computer which consists of a processor assembly and a calibration assembly, Fig. 7. The processor assembly contains the electronic circuitry which performs the following functions within a fraction of a second: a. Choose one of the sensor inputs for evaluation. b. Converts the input to a form usable by the computer to use that signal for calculations. c. Choose the proper operating strategy necessary for the operating conditions. d. Perform spark, EGR, air/fuel ratio, canister purge, throttle kicker and other calculations. e. Send electrical output control signals to the ignition module and control solenoids to adjust timing and dwell, EGR flow rate, thermactor air mode and throttle kicker mode. The processor assembly also contains a separate power supply which provides a continuous reference voltage of about 9 volts nominal to the sensors. The calibration assembly, Fig. 7, contains electronic circuitry which provides calibration equations necessary for specific vehicle application for use by the processor assembly, and provides adjustments for octane problems. The calibration assembly is mounted on the processor assembly. The power relay supplies battery voltage to the EEC system and is mounted on the right hand side of the ECA mounting bracket. It also protects the ECA from possible damage due to reversed polarity. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations RH Fender Apron w/EEC Attached To Top Of RH Fender Apron Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations RH Fender Apron w/EEC Attached To Top Of RH Fender Apron Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Description and Operation Ignition Control Module: Description and Operation Typical Ignition System The Ignition Module shuts off the primary circuit each time it receives a pulse from the magnetic pick-up Fig. 9. A timing circuit in the ignition module turns the primary current back on after a short period of time. High voltage is created each time the magnetic field is built up and collapsed. The red ignition module wire provides operating voltage for the module's electronic components in the Run mode. The white module wire and start bypass provide increased voltage for the module and coil during Start mode. Ignition Modules Dura Spark II systems with UIM (Universal Ignition Module) Fig. 10 can respond to another control signal from either an Ignition Barometric Pressure Switch, Ignition Timing Vacuum Switch, or the Microprocessor Control Unit (MCU), depending on the engine calibration. Responding to this second signal, the UIM provides additional spark timing control for certain operating conditions by shutting off the ignition coil current flow at a different time than with just the distributor pick-up signal. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Description and Operation > Page 1011 Module Identification Chart For proper ignition module identification refer to Fig. 1. The modules are not interchangeable, Dura Spark II has 6 wire connector while Dura Spark III has a 5 wire connector. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Specifications MANIFOLD ABSOLUTE AND BAROMETRIC PRESSURE SENSORS Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Specifications > Page 1017 Barometric Pressure Sensor: Locations In Engine Compartment On RH Fender Apron Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Specifications > Page 1018 Barometric Pressure Sensor: Description and Operation Fig. 5 Barometric & manifold absolute pressure sensor These two sensors, Fig. 5, are combined into one unit. The BMAP sensor monitors the absolute value of the intake manifold pressure and atmospheric pressure (manifold absolute pressure is defined as barometric pressure minus manifold vacuum). Atmospheric pressure changes are converted into an electrical signal and fed to the computer for evaluation. From this input, the computer determines the EGR flow requirements depending on the altitude at which the vehicle is being operated. Intake manifold pressure changes are converted by a pressure-sensing element and electrical circuit by the computer. The signal is used by the computer to determine part throttle spark advance, EGR flow rate and air/fuel ratio. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Testing and Inspection > Barometric Pressure Sensor Barometric Pressure Sensor: Testing and Inspection Barometric Pressure Sensor 1. Disconnect switch from ignition module. 2. Connect suitable ohmmeter across switch terminals and compare resistance measured to values in chart. 3. Replace switch if resistance is not within specifications. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications TEMPERATURE SENSORS Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1024 Coolant Temperature Sensor/Switch (For Computer): Locations RH Side Of V8-302/5. Near Front Of RH Valve Cover Applicable to: 0L & V8-351/5.8L w/EEC Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1025 Coolant Temperature Sensor/Switch (For Computer): Description and Operation This sensor incorporates a thermistor in a brass housing with an integral wiring connector extending from the body. This sensor is installed in the heater outlet fitting of the intake manifold. The thermistor is a resistor whose resistance value is high at low temperatures and decreases as the temperature rises. The computer applies a voltage to the sensor and monitors the resultant voltage drop across the thermistor. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications CRANKSHAFT SENSOR Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 1029 Crankshaft Position Sensor: Locations RH Front Of Engine Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 1030 Crankshaft Position Sensor: Description and Operation Fig.6 - Crankshaft Position Sensor Fig.7 - Crankshaft Position Sensor DESCRIPTION The crankshaft vibration damper is fitted with a four-lobe "pulse ring" which provides the system with an accurate indication of when the pistons reach 10 BTDC. This indication is called the reference timing. Figs. 6 and 7. The pulse ring is a powdered metal ring positioned on the crankshaft vibration damper during manufacture. It has four equally spaced lobes which represent crankshaft position when the pistons reach 10 BTDC. During operation, the lobes on the pulse ring pass by the tip of the CP sensor. The pulse ring interrupts the magnetic field at the tip of the sensor. When the field is interrupted, an output signal is generated and sent to the ECA. As the crankshaft turns, the ECA evaluates the electrical impulses to determine the exact position of the crankshaft at any given time. By the frequency of the impulses, the ECA can determine the engine speed. With these two factors, the ECA will determine the appropriate ignition timing advance required for best engine operation. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Locations EGR Valve Position Sensor: Locations LH Side Of V8-302/5. At Center Engine To Rear Of Carburetor Applicable to: 0L Engine Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Locations > Page 1034 EGR Valve Position Sensor: Description and Operation Fig. 6 EGR valve position sensor This sensor, Fig. 6, is used to monitor the EGR valve pintle position. The computer applies a reference voltage to the EVP sensor, and the resulting signal from the EVP sensor is proportional to the amount of exhaust gases flowing through the EGR valve pintle into the intake manifold. Depending on the input from this and other sensors, the computer can increase or decrease EGR flow by activating or deactivating a pair of solenoid vacuum valves. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications TEMPERATURE SENSORS Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 1038 Intake Air Temperature Sensor: Description and Operation DESCRIPTION This sensor is used on models with fuel injection. It sends air temperature information to the Electronic Control Unit to make changes for air temperature variations. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Component Testing Intake Air Temperature Sensor: Testing and Inspection Component Testing NOTE: Prior to performing any test on this system, insure that temperature switch is above 65° F. 1. Disconnect connector from wiring harness. 2. Connect an ohmmeter or self-powered test light to temperature switch connector terminals. 3. Cool the switch to below 40° F by spraying with Refrigerant 12. CAUTION: Do not spray refrigerant with engine running, as any refrigerant drawn into the carburetor and burned in the engine will produce poisonous phosgene gas. Conduct this procedure in well ventilated area. 4. When switch is cooled below 40° F. a. On type 1 switches, the internal switch contacts should open. The ohmmeter should read maximum resistance or the test light should be off. If switch does not open below 40° F, replace switch. b. On type 2 switches, the internal switch contacts should close. The ohmmeter should read zero resistance and the test light should be on. If test light does not go on or ohmmeter indicates a resistance of 1 ohm or more, replace switch. 5. Increase switch temperature to above 70° F by placing palm of hand on metal surface of switch or by starting engine and allowing the exhaust manifold heat to increase the intake air temperature. 6. When switch temperature is above 70° F. a. On type 1 switches, the internal switch contacts should close. The ohmmeter should read zero resistance and the test light should be on. If test light does not go on or ohmmeter indicates a resistance of 1 ohm or more, replace switch. b. On type 2 switches, the internal switch contacts should open. The ohmmeter should read maximum resistance or the test light should be off. If switch does not open, replace switch. c. If switch is replaced, check operation of new switch before connecting harness connector. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Description and Operation Knock Sensor: Description and Operation Knock Sensor The knock sensor, Fig. 11, is a piezo-electric accelerator accelerometer with the sensor designed to resonate at approximately the same frequency as the engine knock frequency.. The sensor uses the resonant frequency to mechanically amplify the engine knock frequency (5-6 KHz). This method allows relatively large signals to be achieved without electrical amplification. The sensor has a thin circular piezoelectric ceramic disk which is bonded to a metal diaphragm. Electrical connections are made through a two-pin integral connector. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Testing and Inspection > Component Testing Knock Sensor: Testing and Inspection Component Testing Fig.8 - MCU System Wiring Circuit 1. Make sure that the following three steps are properly conducted in order to simulate spark knock conditions and determine that spark detection system is inoperative. If not, repeat test to verify problem. a. Make sure that engine is at normal operating temperature. Run engine at 2000 rpm for 2 minutes, then turn key off. Immediately restart engine and allow to idle. b. Observe voltmeter and vacuum gauge for initialization pulses after restarting the engine. The throttle kicker will also extend (increase engine speed) and remain on throughout the test. c. On vehicles with spark knock sensor, when initial pulses occur, immediately simulate spark knock by placing a 3/8 inch extension on manifold near base of knock sensor. Tap end of extension with a small hammer for about 15 seconds. 2. Disconnect jumper wire from self-test trigger input circuit 201. 3. With ignition key off, disconnect vehicle harness from spark knock sensor. 4. Using a torque wrench and a 1 1/8 inch deep socket, make sure that spark sensor is torqued to 12-18 ft. lbs. If sensor is properly torqued, proceed to next step. If not, torque to specifications. 5. Disconnect vehicle harness from MCU and spark sensor. Connect one lead of an ohmmeter to circuit 310 of vehicle harness and other lead to engine block, Fig. 8. If resistance is 1000 ohms or more, proceed to next step. If resistance is less than 1000 ohms, repair short to ground in circuit 301. 6. With key off and knock sensor harness disconnected, check circuit 310 of vehicle harness for continuity. If resistance is 10 ohms or less, continue to next step. If resistance is greater than 10 ohms, repair circuit 310. 7. Check circuit 60 of vehicle harness for continuity between knock sensor and MCU, Fig. 8. If resistance is 10 ohms or less, reconnect harness connector to MCU and proceed to next step. If resistance is greater than 10 ohms, service circuit 60. 8. Reconnect jumper wire to circuits 201 and 60 of VIP connector, Fig. 8. 9. Connect a test lamp to positive terminal of battery, then disconnect knock sensor from vehicle harness. 10. Perform "Engine Running Functional Test" procedure. When the four initialization pulses occur, continuously tap circuit 310 of the vehicle harness connector, which mates to the knock sensor connector, with the probe end for 5 seconds while observing voltmeter pulses. If a code 25 is Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Testing and Inspection > Component Testing > Page 1046 observed, replace MCU. If any other code is observed, replace spark knock sensor. SPARK KNOCK, ONLY AT WIDE OPEN THROTTLE AND/OR POOR PERFORMANCE/MILEAGE 1. If engine has a spark knock sensor, disconnect it. 2. Make sure that ignition timing is within specifications. 3. With engine running at normal operating temperature, disconnect the two wire ignition module connector (yellow wire is circuit 324 and black/white wire is circuit 69) from vehicle harness. Using a jumper wire, jump the wires together at the ignition module and note ignition timing. Remove jumper wire and note ignition timing. If timing retards 16-20 degrees, reconnect ignition module and proceed to next step. If timing does not retard 16-20 degrees, replace ignition module and repeat steps 1, 2 and 3. 4. With engine at normal operating temperature, set high cam on lowest step that will maintain engine speed greater than 1200 rpm. Note ignition timing, then disconnect and plug vacuum hose from zone vacuum switch and again note timing. If timing retards more than 5 degrees, on engines with spark knock sensor, proceed to step 6, on all other engines MCU system is okay. If timing does not retard more than 5 degrees, proceed to next step. 5. With engine still at 1200 rpm, disconnect ignition module (connector with yellow and black/white wires). If timing retards, check circuit 324 for short to ground. If circuit is okay, replace MCU unit and retest. If timing does not retard, check circuit 324 for open circuit. If circuit is okay, Replace MCU unit and retest. 6. On engines with spark knock sensor, reconnect sensor. Repeat Engine Running Functional Test, but do not simulate knock by taping sensor. If service code 25 appears, MCU system is okay, testing is completed. If any other service code appears, replace knock sensor and retest. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications MANIFOLD ABSOLUTE AND BAROMETRIC PRESSURE SENSORS Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 1050 Manifold Pressure/Vacuum Sensor: Locations RH Fender Apron w/EEC In Engine Compartment On RH Fender Apron Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 1051 Manifold Pressure/Vacuum Sensor: Description and Operation Fig. 5 Barometric & manifold absolute pressure sensor DESCRIPTION These two sensors, Fig. 5, are combined into one unit. The BMAP sensor monitors the absolute value of the intake manifold pressure and atmospheric pressure (manifold absolute pressure is defined as barometric pressure minus manifold vacuum). Atmospheric pressure changes are converted into an electrical signal and fed to the computer for evaluation. From this input, the computer determines the EGR flow requirements depending on the altitude at which the vehicle is being operated. Intake manifold pressure changes are converted by a pressure-sensing element and electrical circuit by the computer. The signal is used by the computer to determine part throttle spark advance, EGR flow rate and air/fuel ratio. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Gas Oxygen (EGO) Sensor <--> [Oxygen Sensor] > Component Information > Locations Exhaust Gas Oxygen (EGO) Sensor: Locations RH Side Of V8-302/5. On Exhaust Manifold RH Side Of Engine Applicable to: 0L & V8-351/5.8L w/EEC Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Exhaust Gas Oxygen (EGO) Sensor <--> [Oxygen Sensor] > Component Information > Locations > Page 1055 Exhaust Gas Oxygen (EGO) Sensor: Description and Operation Fig. 4 Exhaust gas oxygen sensor This sensor, Fig. 4, is installed in the exhaust manifold and provides information to the ECA as to the oxygen content of the exhaust gases. It monitors the oxygen content of the exhaust gases and generates an output of .6 to 1.0 volt when detecting a rich exhaust gas mixture (absence of oxygen) and less than .2 volts when detecting a lean mixture (presence of oxygen). This constantly changing voltage signal is sent to the ECA for analysis. The outer surface of the sensor is a threaded steel housing and shell. The sensor body is protected by a shield pressed into the housing where it projects into the exhaust manifold. Exhaust gases contact the sensor body by entering through flutes in the sensor shield. A vent is provided in the shell to allow atmospheric air to enter the inner portion of the sensor body. The sensor connects to the vehicle wiring harness with a connector that is attached to the inner (positive) terminal. The shell is the negative terminal of the sensor and provides the return signal path through the engine block. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications THROTTLE POSITION SENSOR SPECIFICATIONS Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 1059 Throttle Position Sensor: Description and Operation Fig. 2 Throttle position sensor (typical) This sensor, Fig. 2, is basically a rheostat switch attached to the carburetor throttle shaft and responds to throttle valve angle changes. The throttle angles are classified into three operating modes as follows: a. Closed Throttle (Idle or Deceleration) b. Part Throttle c. Wide Open Throttle (Maximum Acceleration) The ECA applies a reference voltage of about 9 volts to the sensor. The resultant sensor voltage supplied to the ECA, which is determined by the throttle position, is used by the ECA to determine the proper amount of spark advance, EGR flow, air/fuel ratio and thermactor air mode. The throttle position sensor mounting holes are slotted to permit adjustment. If the sensor is replaced, it must be correctly positioned or incorrect throttle information will be sent to the ECA. The adjustment requires use of special electronic test equipment. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 1060 Throttle Position Sensor: Adjustments Engines with EEC III Turn ignition to RUN position and remove vacuum hose from throttle kicker, as equipped. With engine not running, compare voltage reading against specifications and adjust as needed. Engines with EEC IV Connect positive probe of DVOM along terminal C (lower) of TPS and connect negative probe along terminal A (upper). Turn ignition on but do not start vehicle. Adjust TPS to specified value. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations At LH Side Of Dash Panel Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Speed Sensor Test Vehicle Speed Sensor: Testing and Inspection Speed Sensor Test 1980-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986-87 Aerostar 1. Disconnect 6 way connector from amplifier assembly, then connect an ohmmeter between dark green wire w/white stripe and black wire on 1980 E-100-350, 1981-83 F-100-350 models and Bronco, and 1984-87 F-150-350 and Bronco, or green and black wire on 1980 F-100-350 and 1981-83 E-100-350 models and 1984-87 E-150-350 at the speed sensor end. A reading of 40 ohms should be obtained. A reading of 0 ohms indicates a shorted coil and an infinity reading indicates an open coil. 2. Replace sensor if a correct reading has not been obtained. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Page 1066 Vehicle Speed Sensor: Service and Repair 1. Separate electrical connector leading to the amplifier assembly. 2. Disconnect upper and lower speedometer cables at the speed sensor. Remove speed sensor. 3. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Locations EGR Valve Position Sensor: Locations LH Side Of V8-302/5. At Center Engine To Rear Of Carburetor Applicable to: 0L Engine Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Locations > Page 1071 EGR Valve Position Sensor: Description and Operation Fig. 6 EGR valve position sensor This sensor, Fig. 6, is used to monitor the EGR valve pintle position. The computer applies a reference voltage to the EVP sensor, and the resulting signal from the EVP sensor is proportional to the amount of exhaust gases flowing through the EGR valve pintle into the intake manifold. Depending on the input from this and other sensors, the computer can increase or decrease EGR flow by activating or deactivating a pair of solenoid vacuum valves. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Tank Selector Switch > Component Information > Locations Fuel Tank Selector Switch: Locations LH Side Of I/P Near Fuse Panel Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pump Inertia Switch: > 831112S > Sep > 84 > Fuel System - Stalls/No Start/Hesitation/ Stumble Fuel Pump Inertia Switch: Customer Interest Fuel System - Stalls/No Start/Hesitation/ Stumble Article No. 83-11-12-S STALLS/NO START/HESITATION/ STUMBLE - VAPOR LOCK (5.8L, 6.6L 7.5L) - VEHICLES OVER 8500 LBS. GVW LIGHT TRUCKS 1980/82 E250/350, F250/350 The service part numbers for kits "D" and "E" have been changed from E2UZ-9350-B to E0UZ-9350-D (Kit D) and E2UZ-9350-C to E0UZ-9350-C (Kit E) in TSB 83-11-12. The TSB Article is being reprinted showing the correct part numbers. NOTE: This TSB replaces TSB 82-14-21 dated July 16, 1982 in its entirety. DO NOT attempt to use TSB 82-14-21 to order service parts. Loss of road speed, hesitation, or engine stall on the subject vehicles operated at ambient temperatures over 85~F or at elevations over 4,500 feet, may be the result of fuel vaporization. A modification kit is available for vehicles experiencing this condition. It consists of an in-tank fuel pump, inertia shut-off switch, motorized fuel selector valve, vapor separator, and a vapor return system, along with related fuel lines and electrical wiring and devices. Before this modification is considered, other factors that could result in the same symptoms should be evaluated. Some of these include: ^ Plugged fuel filter at carburetor or tank. ^ Restricted fuel line. ^ Contaminated or low quality fuel. ^ Malfunctioning fuel pump or carburetor. If it is determined that the above factors have not caused the customer concern then the appropriate modification kit should be used to change the fuel system. Hardware Required: Components required to modify the vehicle differ with vehicle series, engine model and type of fuel tank. These have been packaged into 13 different kits. The chart that follows describes the specific kits that are required for the various vehicle configurations. Continued on next page TANK ENGINE (CID) KITS REQUIRED F-Series Single (Midship) 351M/400 A, F, H Single (Plastic Aft Axle) 351M/400 F, C, L Single (Metal Aft Axle) 351M/400 B, F, L Dual (Steel Aft Axle) 351M/400 A, B, F, I Dual (Plastic Aft Axle) 351M/400 A, C, F, I E-Series Single (Aft Axle) 351M/400 D, F, J Dual 351M/400 D, E, F, K E-Series Single (Aft Axle) 7.5L 460 D, G, J Dual 7.5L 460 D, E, G, K KIT SERVICE PART NO. DESCRIPTION CLASS A E2TZ-9350-D Fuel Pump/Sender Kit CG B E2TZ-9350-F Fuel Pump/Sender Kit CG C E2TZ-9350-C Fuel Pump/Sender Kit CG D E0UZ-9350-D Fuel Pump/Sender Kit CG E E0UZ-9350-C Fuel Pump/Sender Kit CG F E0TZ-9B328-A Vapor Separator Kit CG G E0TZ-9B328-B Vapor Separator Kit CG H E2TZ-9A350-H Fuel Line/Electrical Kit CG I E2TZ-9A350-F Fuel Line/Electrical Kit CG J E2UZ-9A350-F Fuel Line/Electrical Kit CG K E2UZ-9A350-D Fuel Line/Electrical Kit CG L E2TZ-9350-G Fuel Line/Electrical Kit CG Select the appropriate kit required; the detailed installation instructions will be supplied with each kit. OTHER APPLICABLE ARTICLES: 83-11-12 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pump Inertia Switch: > 831112S > Sep > 84 > Fuel System - Stalls/No Start/Hesitation/ Stumble > Page 1084 ARTICLES SUPERSEDED: 82-14-21; 83-11-23 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. DLR. CODING: Basic Part No. 9237 Code: H6 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pump Inertia Switch: > 831112S > Sep > 84 > Fuel System - Stalls/No Start/Hesitation/ Stumble Fuel Pump Inertia Switch: All Technical Service Bulletins Fuel System - Stalls/No Start/Hesitation/ Stumble Article No. 83-11-12-S STALLS/NO START/HESITATION/ STUMBLE - VAPOR LOCK (5.8L, 6.6L 7.5L) - VEHICLES OVER 8500 LBS. GVW LIGHT TRUCKS 1980/82 E250/350, F250/350 The service part numbers for kits "D" and "E" have been changed from E2UZ-9350-B to E0UZ-9350-D (Kit D) and E2UZ-9350-C to E0UZ-9350-C (Kit E) in TSB 83-11-12. The TSB Article is being reprinted showing the correct part numbers. NOTE: This TSB replaces TSB 82-14-21 dated July 16, 1982 in its entirety. DO NOT attempt to use TSB 82-14-21 to order service parts. Loss of road speed, hesitation, or engine stall on the subject vehicles operated at ambient temperatures over 85~F or at elevations over 4,500 feet, may be the result of fuel vaporization. A modification kit is available for vehicles experiencing this condition. It consists of an in-tank fuel pump, inertia shut-off switch, motorized fuel selector valve, vapor separator, and a vapor return system, along with related fuel lines and electrical wiring and devices. Before this modification is considered, other factors that could result in the same symptoms should be evaluated. Some of these include: ^ Plugged fuel filter at carburetor or tank. ^ Restricted fuel line. ^ Contaminated or low quality fuel. ^ Malfunctioning fuel pump or carburetor. If it is determined that the above factors have not caused the customer concern then the appropriate modification kit should be used to change the fuel system. Hardware Required: Components required to modify the vehicle differ with vehicle series, engine model and type of fuel tank. These have been packaged into 13 different kits. The chart that follows describes the specific kits that are required for the various vehicle configurations. Continued on next page TANK ENGINE (CID) KITS REQUIRED F-Series Single (Midship) 351M/400 A, F, H Single (Plastic Aft Axle) 351M/400 F, C, L Single (Metal Aft Axle) 351M/400 B, F, L Dual (Steel Aft Axle) 351M/400 A, B, F, I Dual (Plastic Aft Axle) 351M/400 A, C, F, I E-Series Single (Aft Axle) 351M/400 D, F, J Dual 351M/400 D, E, F, K E-Series Single (Aft Axle) 7.5L 460 D, G, J Dual 7.5L 460 D, E, G, K KIT SERVICE PART NO. DESCRIPTION CLASS A E2TZ-9350-D Fuel Pump/Sender Kit CG B E2TZ-9350-F Fuel Pump/Sender Kit CG C E2TZ-9350-C Fuel Pump/Sender Kit CG D E0UZ-9350-D Fuel Pump/Sender Kit CG E E0UZ-9350-C Fuel Pump/Sender Kit CG F E0TZ-9B328-A Vapor Separator Kit CG G E0TZ-9B328-B Vapor Separator Kit CG H E2TZ-9A350-H Fuel Line/Electrical Kit CG I E2TZ-9A350-F Fuel Line/Electrical Kit CG J E2UZ-9A350-F Fuel Line/Electrical Kit CG K E2UZ-9A350-D Fuel Line/Electrical Kit CG L E2TZ-9350-G Fuel Line/Electrical Kit CG Select the appropriate kit required; the detailed installation instructions will be supplied with each kit. OTHER APPLICABLE ARTICLES: 83-11-12 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pump Inertia Switch: > 831112S > Sep > 84 > Fuel System - Stalls/No Start/Hesitation/ Stumble > Page 1090 ARTICLES SUPERSEDED: 82-14-21; 83-11-23 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. DLR. CODING: Basic Part No. 9237 Code: H6 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications THROTTLE POSITION SENSOR SPECIFICATIONS Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 1094 Throttle Position Sensor: Description and Operation Fig. 2 Throttle position sensor (typical) This sensor, Fig. 2, is basically a rheostat switch attached to the carburetor throttle shaft and responds to throttle valve angle changes. The throttle angles are classified into three operating modes as follows: a. Closed Throttle (Idle or Deceleration) b. Part Throttle c. Wide Open Throttle (Maximum Acceleration) The ECA applies a reference voltage of about 9 volts to the sensor. The resultant sensor voltage supplied to the ECA, which is determined by the throttle position, is used by the ECA to determine the proper amount of spark advance, EGR flow, air/fuel ratio and thermactor air mode. The throttle position sensor mounting holes are slotted to permit adjustment. If the sensor is replaced, it must be correctly positioned or incorrect throttle information will be sent to the ECA. The adjustment requires use of special electronic test equipment. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 1095 Throttle Position Sensor: Adjustments Engines with EEC III Turn ignition to RUN position and remove vacuum hose from throttle kicker, as equipped. With engine not running, compare voltage reading against specifications and adjust as needed. Engines with EEC IV Connect positive probe of DVOM along terminal C (lower) of TPS and connect negative probe along terminal A (upper). Turn ignition on but do not start vehicle. Adjust TPS to specified value. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications CRANKSHAFT SENSOR Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 1100 Crankshaft Position Sensor: Locations RH Front Of Engine Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 1101 Crankshaft Position Sensor: Description and Operation Fig.6 - Crankshaft Position Sensor Fig.7 - Crankshaft Position Sensor DESCRIPTION The crankshaft vibration damper is fitted with a four-lobe "pulse ring" which provides the system with an accurate indication of when the pistons reach 10 BTDC. This indication is called the reference timing. Figs. 6 and 7. The pulse ring is a powdered metal ring positioned on the crankshaft vibration damper during manufacture. It has four equally spaced lobes which represent crankshaft position when the pistons reach 10 BTDC. During operation, the lobes on the pulse ring pass by the tip of the CP sensor. The pulse ring interrupts the magnetic field at the tip of the sensor. When the field is interrupted, an output signal is generated and sent to the ECA. As the crankshaft turns, the ECA evaluates the electrical impulses to determine the exact position of the crankshaft at any given time. By the frequency of the impulses, the ECA can determine the engine speed. With these two factors, the ECA will determine the appropriate ignition timing advance required for best engine operation. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Service and Repair Ignition Switch: Service and Repair Fig. 3 Ignition switch replacement 1. Disconnect battery ground cable. 2. Remove steering column shroud and lower the steering column. 3. Disconnect electrical connector from switch, then remove 2 switch attaching nuts. 4. Lift switch up to disengage actuator rod, then remove switch from vehicle, Fig. 3. 5. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation Knock Sensor: Description and Operation Knock Sensor The knock sensor, Fig. 11, is a piezo-electric accelerator accelerometer with the sensor designed to resonate at approximately the same frequency as the engine knock frequency.. The sensor uses the resonant frequency to mechanically amplify the engine knock frequency (5-6 KHz). This method allows relatively large signals to be achieved without electrical amplification. The sensor has a thin circular piezoelectric ceramic disk which is bonded to a metal diaphragm. Electrical connections are made through a two-pin integral connector. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Testing and Inspection > Component Testing Knock Sensor: Testing and Inspection Component Testing Fig.8 - MCU System Wiring Circuit 1. Make sure that the following three steps are properly conducted in order to simulate spark knock conditions and determine that spark detection system is inoperative. If not, repeat test to verify problem. a. Make sure that engine is at normal operating temperature. Run engine at 2000 rpm for 2 minutes, then turn key off. Immediately restart engine and allow to idle. b. Observe voltmeter and vacuum gauge for initialization pulses after restarting the engine. The throttle kicker will also extend (increase engine speed) and remain on throughout the test. c. On vehicles with spark knock sensor, when initial pulses occur, immediately simulate spark knock by placing a 3/8 inch extension on manifold near base of knock sensor. Tap end of extension with a small hammer for about 15 seconds. 2. Disconnect jumper wire from self-test trigger input circuit 201. 3. With ignition key off, disconnect vehicle harness from spark knock sensor. 4. Using a torque wrench and a 1 1/8 inch deep socket, make sure that spark sensor is torqued to 12-18 ft. lbs. If sensor is properly torqued, proceed to next step. If not, torque to specifications. 5. Disconnect vehicle harness from MCU and spark sensor. Connect one lead of an ohmmeter to circuit 310 of vehicle harness and other lead to engine block, Fig. 8. If resistance is 1000 ohms or more, proceed to next step. If resistance is less than 1000 ohms, repair short to ground in circuit 301. 6. With key off and knock sensor harness disconnected, check circuit 310 of vehicle harness for continuity. If resistance is 10 ohms or less, continue to next step. If resistance is greater than 10 ohms, repair circuit 310. 7. Check circuit 60 of vehicle harness for continuity between knock sensor and MCU, Fig. 8. If resistance is 10 ohms or less, reconnect harness connector to MCU and proceed to next step. If resistance is greater than 10 ohms, service circuit 60. 8. Reconnect jumper wire to circuits 201 and 60 of VIP connector, Fig. 8. 9. Connect a test lamp to positive terminal of battery, then disconnect knock sensor from vehicle harness. 10. Perform "Engine Running Functional Test" procedure. When the four initialization pulses occur, continuously tap circuit 310 of the vehicle harness connector, which mates to the knock sensor connector, with the probe end for 5 seconds while observing voltmeter pulses. If a code 25 is Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Testing and Inspection > Component Testing > Page 1110 observed, replace MCU. If any other code is observed, replace spark knock sensor. SPARK KNOCK, ONLY AT WIDE OPEN THROTTLE AND/OR POOR PERFORMANCE/MILEAGE 1. If engine has a spark knock sensor, disconnect it. 2. Make sure that ignition timing is within specifications. 3. With engine running at normal operating temperature, disconnect the two wire ignition module connector (yellow wire is circuit 324 and black/white wire is circuit 69) from vehicle harness. Using a jumper wire, jump the wires together at the ignition module and note ignition timing. Remove jumper wire and note ignition timing. If timing retards 16-20 degrees, reconnect ignition module and proceed to next step. If timing does not retard 16-20 degrees, replace ignition module and repeat steps 1, 2 and 3. 4. With engine at normal operating temperature, set high cam on lowest step that will maintain engine speed greater than 1200 rpm. Note ignition timing, then disconnect and plug vacuum hose from zone vacuum switch and again note timing. If timing retards more than 5 degrees, on engines with spark knock sensor, proceed to step 6, on all other engines MCU system is okay. If timing does not retard more than 5 degrees, proceed to next step. 5. With engine still at 1200 rpm, disconnect ignition module (connector with yellow and black/white wires). If timing retards, check circuit 324 for short to ground. If circuit is okay, replace MCU unit and retest. If timing does not retard, check circuit 324 for open circuit. If circuit is okay, Replace MCU unit and retest. 6. On engines with spark knock sensor, reconnect sensor. Repeat Engine Running Functional Test, but do not simulate knock by taping sensor. If service code 25 appears, MCU system is okay, testing is completed. If any other service code appears, replace knock sensor and retest. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications SPECIFICATIONS Pressure .............................................................................................................................................. .............................................................. 6.0-8.0 PSI Volume .............................................................. ................................................................................................................................. 1 pint in 20 seconds NOTE: Measurements taken with engine idling. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications > Page 1115 Fuel Pressure: Testing and Inspection PRESSURE TEST 1. Connect a suitable pressure gauge (0-15 PSI) to the carburetor end of the fuel line. WARNING: Use care to prevent combustion of spilled fuel. 2. Start the engine (it should be able to run for over 30 seconds on the fuel in the carburetor bowl) and read the pressure after 10 seconds. If pump pressure is too low or too high install a new fuel pump. Fuel Pump Pressure ............................................................................................................................ ................................................. 6.0-8.0 PSI 3. Reconnect fuel line at filter and install air cleaner. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications IDLE SPEED SPECIFICATIONS Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Curb Idle Speed Idle Speed: Adjustments Curb Idle Speed Identification CARBURETOR IDENTIFICATION 2150-2V, 2150A-2V Carburetor Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Curb Idle Speed > Page 1121 Variable Venturi, 7200-VV Carburetor Type 2150-2V CURB IDLE SPEED ADJUSTMENT - Place the transmission in Neutral (manual) or Park (automatic). - Bring engine to normal operating temperature (upper radiator hose hot). - Place the transmission in the specified gear. See: Specifications Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Curb Idle Speed > Page 1122 - Check curb idle rpm. Adjust to specification. See: Specifications - Place the transmission in Neutral (manual) or Park (automatic). Rev the engine momentarily. Place the transmission in specified position, and recheck curb idle rpm. Readjust if required. Type 7200-VV Carburetor CURB IDLE SPEED ADJUSTMENT - Place the transmission in Neutral (manual) or Park (automatic). - Bring the engine to normal operating temperature. - Disconnect purge hose on canister side of evaporator purge solenoid. Check to ensure that purge vacuum is present (solenoid has opened, will require a 3-5 minute wait after starting engine, followed by a short time at part throttle. Reconnect purge hose. - Disconnect and plug the vacuum hose to the Vacuum Operated Throttle Modulator (VOTM) kicker. - Place the transmission in specified position. See: Specifications With Automatic Transmission Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Curb Idle Speed > Page 1123 With Manual Transmission - Check/adjust curb idle rpm. See: Specifications - Place the transmission in Neutral or Park. Rev the engine momentarily. Place the transmission in specified position and recheck curb idle rpm. Readjust if required. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Curb Idle Speed > Page 1124 Idle Speed: Adjustments Fast Idle Speed Identification CARBURETOR IDENTIFICATION 2150-2V, 2150A-2V Carburetor Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Curb Idle Speed > Page 1125 Variable Venturi, 7200-VV Carburetor Type 2150-2V Carburetor FAST IDLE SPEED ADJUSTMENT - Place the transmission in Park (automatic) or Neutral (manual). - Bring the engine to normal operating temperature. - Disconnect the vacuum hose at the EGR valve and plug. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Adjustments > Curb Idle Speed > Page 1126 - Place the fast idle adjustment mechanism on top step of fast idle cam. Check/adjust fast idle rpm to specification. See: Specifications - Recheck for repeatability. - Remove the plug from the EGR vacuum hose and reconnect. Type 7200-VV Carburetor FAST IDLE SPEED ADJUSTMENT - Place the transmission in Neutral (manual) or Park (automatic). - Bring the engine to normal operating temperature. - Disconnect purge hose on canister side of evaporator purge solenoid. Check to ensure that purge vacuum is present (solenoid has opened, will require a 3-5 minute wait after starting engine, followed by a short time at part throttle. Reconnect purge hose. Disconnect the vacuum hose at the EGR valve and plug. - Place the fast idle adjustment mechanism on the second step of the fast idle cam. - Check/adjust fast idle rpm to specification. Recheck for repeatability. See: Specifications - Remove the plug from the EGR vacuum hose and reconnect. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Technical Service Bulletins > Air Cleaner - Sealing Procedure Air Cleaner Housing: Technical Service Bulletins Air Cleaner - Sealing Procedure Article No. 83-25-21-S AIR CLEANER SEALING - 4.9L (1982-83 F-SERIES AND BRONCO ONLY) AND ALL UNITS WITH 5.0L, 5.8L OR 7.5L ENGINES. UNITS OPERATED IN DUSTY AND/OR OFF-ROAD CONDITIONS ARTICLE ALSO INCLUDES SEALING OF 7200VV CARBURETOR ON UNITS SO EQUIPPED LIGHT TRUCKS 1980-83 E, F AND BRONCO This is a re-write of TSB 83-25-21 (December 12, 1983). The air cleaner part numbers listed in the TSB are of insufficient detail and are therefore being deleted from the TSB. Due to the variety of different air cleaners used, part numbers have not been included in this TSB. See your normal parts listing for these part numbers. The subject vehicles operated in dusty/off-road conditions may experience an air cleaner sealing concern which could lead to engine oil consumption or, on 7200 VV carburetor equipped vehicles, a poor running condition. The following procedure should minimize these concerns. 1. Remove the air cleaner assembly from the engine and remove any loose debris from inside the tray. Replace the air cleaner assembly (9600) on all 1983 4.9L, 5.0L, 5.8L and, 7.5L equipped light trucks except the 1983 Econoline with the 4.9L engine. Due to the variety of different air cleaners used, part numbers have not been included in this TSB. See your normal parts listings for these part numbers. 2. Wipe the sealing surfaces clean on the tray and cover and inspect for any dents or damage that would prevent a good seal. Replace any damaged components. 3. Inspect the air cleaner to carburetor gasket for proper installation. If the gasket appears crimped or damaged, replace it with a new sticky-back gasket. Prior to replacing the gasket, clean the carburetor flange. Install the new gasket sticky side down and press all the gasket down to assure a tight bond. Gasket parts numbers: 4.9L - C8DZ-9654-A, 5.0L/5.8L/7.5L - D8ZZ-9654-A. FIGURE 24 4. For F-Series and Bronco only, relocate the zip tube inlet. a) Detach the zip tube inlet from the radiator support. b) Move the inlet to the top rear of the wheel wellhousing per Figure 24. c) Secure the zip tube to the top of the housing with a nylon tie-down strap. NOTE: At high temperatures, an octane ping may occur. If it persists, the zip tube must be reinstalled to the radiator support. 5. Replace the PCV filter. For 4.9L, 5.0L-2V, 5.8L-2V and 7.5L-4V engines replace the PCV filter in the air cleaner with an in-line filter. a. Remove and discard the crankcase breather cap to PCV filter hose (closure hose), PCV filter in the air cleaner, the adapter at the air cleaner and the adapter retaining clip. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Technical Service Bulletins > Air Cleaner - Sealing Procedure > Page 1131 b. Drill a 5/16" hole in the side wall of the air cleaner approximately 12" to the rear of the existing crankcase closure hole for 5.0L and 5.8L and approximately 6" to the rear on 7.5L. (The 4.9L does not need a new hole). c. Install a 1/2" hose (E2AZ-6853-A) to the existing adaptor in the valve cover oil fill cap (2 pcs. 2-5/8" long for 4.9L, 18" long for 5.0L/5.8L, 12" long for 7.5L). d. At a convenient location, cut the hose and install an in-line filter E2AZ-6A768-A for 5.0L, 5.8L and 7.5L. On the 4.9L, install the filter between the 2-5/8" long pieces installed in (c.). NOTE: Install the filter with the wire mesh toward the oil fill cap. The mesh can be seen by looking into the end of the filter assembly. e. Install an adapter E43Z-9E606-A in the air cleaner and attach using a retaining clip 383741-S. Center the adapter elbow in the new hole for 5.0L, 5.8L and 7.5L. Use the existing PCV filter (closure) pack hole for 4.9L. f. Cut the PCV filter (closure) hose to proper length and attach to the adapter. g. Plug the old hole in the tray with plug 377678-S for 5.0L, 5.8L and 7.5L only. FIGURE 25 6. For 5.0L and 5.8L engines with a 7200 VV carburetor, clean and seal the carburetor to prevent dirt migration through the choke rod and accelerator pump rod holes (Refer to Figure 25). a. Remove the carburetor from the vehicle. b. Without disassembling the carburetor, thoroughly clean with Ford Automatic Choke Cleaner or equivalent, all of the choke linkage and accelerator pump linkage on the top and sides of the carburetor. Pay particular attention to the top and bottom of the upper body casting around the choke and accelerator pump rods. Allow cleaner to evaporate or blow dry with shop air. c. Remove stepper motor, gasket, pintle and spring. Clean pintle and pintle cavity in main body casting thoroughly with Ford Automatic Choke Cleaner or equivalent. Do not re-install stepper motor at this time. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Technical Service Bulletins > Air Cleaner - Sealing Procedure > Page 1132 FIGURE 24 d. Hold throttle lever in the wide-open throttle position to raise the accelerator pump rod. With a toothpick, or other sharp tool, apply any commercially available silicone RTV (such as Dow Corning "Silastic") to the top side of the upper body casting around the accelerator pump rod (Figure 24). Fill the hole completely around the rods from the top side only and release the throttle lever. e. With a rubber band, tie the throttle lever in closed-throttle position. Push fast idle cam to "off" position so that choke rod is fully raised. Fast idle cam should remain in "off" position. f. With a toothpick, apply silicone RTV to bottom side of upper body casting around the choke shaft rod. Fill the hole completely around the rod from the bottom side only. g. Install the spring, pintle, gasket, and stepper motor. h. Allow carburetor to stand at room temperature for 24 hours without disturbing silicone RTV. i. After 24-hour cure, remove rubber band from throttle lever, and open throttle to break (free) accelerator pump rod from silicone RTV. Bulk of RTV sealant should remain attached to upper body. j. Manually exercise choke linkage to break (free) choke rod from silicone RTV. Bulk of RTV sealant should remain attached to upper body. k. Re-install carburetor on vehicle. 7. Re-install and secure the air cleaner assembly as follows: a. Set the air cleaner tray assembly on the carburetor and check that nothing is preventing the tray seating securely and completely sealing the flange. b. Connect and secure the vacuum hoses. c. Install and seat a new heavy duty air cleaner element in the tray. Use E2TZ-9601-B (FA-732) for 4.9L and E0TZ-9601-A (FA-688) for 5.0L/5.8L. Use non-heavy duty element for 7.5L. NOTE: Use of incorrect element will allow dirt to be ingested and will damage the engine. d. Install the air cleaner cover and place the washer grommet rubber side down. Torque the wing nut hand tight (20 in.lbs.). Try to rotate the air cleaner assembly slightly. If it resists rotation, sealing to the carburetor is assured. e. Connect the crankcase filter hose securely. f. Install the heat riser tube. Connect the fresh air zip tube. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component Information > Technical Service Bulletins > Air Cleaner - Sealing Procedure > Page 1133 Obtain an Authorized Modifications decal and list the date, dealer number and summary of alterations performed. Select a prominent place adjacent to the Vehicle Emission Control Information decal suitable for installing the Authorized Modifications decal. Clean the area, install the decal and cover it with a clear plastic decal shield. PART NUMBER PART NAME CLASS E2AZ-6A768-A PCV Filter C E2AZ-6853-A 1/2" PCV Hose C E43Z-9E606-A Adapter C E2TZ-9601-B Air Filter Element AM E0TZ-9601-A Air Filter Element AM C6TZ-9697-A Washer AM D8ZZ-9654-A Gasket A 377678-S Plug BR E3AZ-19562-A RTV Sealer A 390013-S36B Wing Nut S C8DZ-9654-A Gasket AM OTHER APPLICABLE ARTICLES: 83-25-21 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP9600C84 TIME: 6 cyl. - 0.5 Hr. 8 cyl. - 1.1 Hrs. DLR. CODING: Basic Part No. 9600 Code: 49 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Technical Service Bulletins > Fuel Filter - Replacement Information Fuel Filter: Technical Service Bulletins Fuel Filter - Replacement Information Article No. 85-6-10 FUEL FILTER REPLACEMENT INFORMATION - ALL WITH FUEL FILTERS ATTACHED TO THE CARBURETOR AND/OR FUEL LINE WITH A RUBBER HOSE FORD ALL 1985 AND PRIOR LINCOLN-MERCURY ALL 1985 AND PRIOR LIGHT TRUCK ALL 1985 AND PRIOR New fuel connector hoses and clamps should be used whenever a fuel filter is replaced. Due to possible deterioration of hose materials which may result if a vehicle is fueled with gasoline containing excessive levels of methanol or ethanol, a new fuel hose and clamps should be installed when the fuel filter is changed. DO NOT REUSE OLD HOSES OR CLAMPS. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Screw In Type Fuel Filter: Service and Repair Screw In Type REMOVAL 1. Remove the air cleaner assembly. 2. Loosen and remove the fuel tube from the filter. 3. Unscrew the filter from the carburetor. INSTALLATION 1. Apply one drop of thread sealer to the external thread of a new filter. Thread the filter into the carburetor inlet port. 2. Tighten the filter to 9.0-11.0 Nm (80-100 in-lbs). 3. Apply ESE-M2C39-E or equivalent oil to the fuel supply tube nut and flare , and hand start the nut into the fuel filter inlet approximately two threads. 4. Use an 11/16 inch wrench on the fuel filter to prevent the filter from rotating. Tighten the fuel filter to supply tube nut to 20-24 Nm (15-18 ft-lb). 5. Install air cleaner assembly. 6. Start the engine and check for fuel leaks. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Component Information > Service and Repair > Screw In Type > Page 1140 Fuel Filter: Service and Repair Inlet Fitting Type REMOVAL - Remove the air cleaner. - Hold the fuel filter inlet hex nut with a backup wrench and unscrew the fuel line tube nut from the fuel filter inlet. WARNING: Use care to prevent combustion from fuel spillage. - Unscrew the fuel inlet fitting. Remove the gasket, filter and spring. - Discard the gasket and filter. INSTALLATION - Install the spring, new filter and gasket. - Hand start the fuel inlet fitting into the carburetor then, tighten to 10-24 Nm (90-125 lb-in). - Apply oil, ESE-M2C39-E or equivalent to the fuel tube nut threads and tube flare. - Hand start the fuel line tube nut into the fuel inlet fitting (approximately two threads). - Use a backup wrench on the fuel inlet fitting while tightening the fuel line tube nut to 20-24 Nm (15-18 lb-ft). - Start the engine and check for fuel leak. - Install the air cleaner. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > With EEC III Firing Order: Specifications With EEC III With EEC III The cylinders are numbered 1-4 on the Right side, starting with the front, and 5-8 on the left side, ending with the rear. Because of the unique dual level rotor used by the EEC-III Ignition system, the engine's firing order cannot be read off the top of Firing Order 1-3-7-2-6-5-4-8 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications > With EEC III > Page 1145 Firing Order: Specifications Without EEC III Without EEC III Firing Order 1-3-7-2-6-5-4-8 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Description and Operation Ignition Timing Connector: Description and Operation Fig. 20 Ignition Timing Vacuum Switch Below vacuum setting, this switch, Fig. 20, used on some vehicles, is open and signals the ignition module to retard spark timing. The switch is closed above the vacuum setting and the ignition module is in the non-retard spark timing mode. Calibration resistors inside the switch control the amount of retard. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Description and Operation > Page 1150 Ignition Timing Connector: Testing and Inspection Ignition Timing Vacuum Switch Ignition Timing Vacuum Switch Test Chart 1. Disconnect switch from ignition module. 2. Connect suitable ohmmeter across switch terminals and compare resistance measured to ``less than'' values in the Ignition Timing vacuum Switch Test chart. 3. Apply vacuum to switch, using an outside vacuum source. Compare resistance now measured across switch terminals to ``greater than'' values in the Ignition Timing vacuum Switch Test chart. 4. Replace switch if resistance is not within specifications. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations > With Electronic Engine Controls (EEC) Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations > With Electronic Engine Controls (EEC) > Page 1155 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Diagrams Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams Ignition Cable: Diagrams Spark Plug Wire Routing Ford F 250 5.8L Firing Order Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Page 1162 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Page 1163 Ignition Cable: Testing and Inspection Spark Plug Wire Resistance *** UPDATED BY TSB #85-9-33 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Advance Unit > Component Information > Specifications DISTRIBUTOR TIMING ADVANCE Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Advance Unit > Component Information > Description and Operation > Vacuum Spark Advance Mechanism Distributor Advance Unit: Description and Operation Vacuum Spark Advance Mechanism The vacuum spark control mechanism can provide spark advance if a single diaphragm assembly is used or spark advance and retard if a dual diaphragm assembly is used. The diaphragm assembly used depends on the engine calibration. Single Diaphragm Assembly SINGLE DIAPHRAGM ASSEMBLY The single diaphragm assembly, Fig. 11, also changes the armature to stator relationship to give spark advance. The stator assembly position is changed by means of vacuum being applied to the diaphragm assembly. Vacuum applied to the diaphragm assembly causes the diaphragm and attached diaphragm rod to move, compressing the advance spring, which controls the rate of advance. The movement of the diaphragm rod, which is attached to the stator assembly, makes the the stator assembly move with respect to the armature. This changes the initial armature to stator relationship set during initial timing, causing spark advance. The stator assembly is mounted on the lower plate assembly which with the diaphragm assembly, is attached to the distributor base. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Advance Unit > Component Information > Description and Operation > Vacuum Spark Advance Mechanism > Page 1170 Dual Diaphragm Assembly DUAL DIAPHRAGM ASSEMBLY The dual diaphragm assembly, Fig. 12, obtains spark advance in the same manner as the single diaphragm assembly. In this case vacuum applied to the vacuum advance port causes the advance diaphragm and attached rod to move, otherwise the action is the same. Spark retard is done by applying vacuum to the vacuum retard port. This causes the retard diaphragm to move, compressing the retard spring, which controls the rate of spark retard. Compressing the retard spring allows the diaphragm rod stop to move due to the force applied by the advance spring pushing against it by means of the diaphragm rod. The result is the diaphragm rod moves causing the attached stator assembly to change position with respect to the armature. In this instance the direction of the stator assembly movement is opposite that occurring during vacuum advance, resulting in spark retard. NOTE: Any vacuum applied to the advance port overrides any spark retard caused by vacuum being applied to the retard port. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Advance Unit > Component Information > Description and Operation > Vacuum Spark Advance Mechanism > Page 1171 Distributor Advance Unit: Description and Operation Centrifugal Spark Advance Mechanism Distributor - Exploded view The centrifugal advance mechanism varies the relationship of the armature to the stator assembly. The armature is mounted to the sleeve and plate assembly which rotates in relation to the distributor shaft. The rotation is a result of the centrifugal weights moving in response to engine RPM. The movement of the weights change the initial relationship of the armature to the stator assembly by rotating the sleeve and plate assembly ahead of its static position on the distributor shaft Fig. 1. This produces spark advance. The rate of movement of the weights is controlled by calibrated springs. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Advance Unit > Component Information > Description and Operation > Page 1172 Distributor Advance Unit: Service and Repair 1. Remove distributor cap and rotor. 2. Disconnect vacuum lines, then remove snap ring that secures vacuum advance link to pickup assembly. 3. Remove vacuum advance attaching screws, then tilt unit downward to disconnect link. 4. Carefully remove unit from distributor. 5. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Retard Control > Component Information > Locations Distributor Retard Control: Locations Below Vacuum Switch Between No. 5 & No. 6 Spark Plugs Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Vacuum Control > Component Information > Description and Operation Distributor Vacuum Control: Description and Operation 3-Port Vacuum Regulator Vacuum Regulator (3 & 4 Port) Three port, Fig. 27, regulators and four port, Fig. 28, regulators are used to control the vacuum advance to the distributor. During engine idle conditions, the manifold vacuum signal is reduced to a constant output signal. Off idle, the output signal equals the spark port. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Vacuum Control > Component Information > Testing and Inspection > Distributor Modulator Valve Assembly Distributor Vacuum Control: Testing and Inspection Distributor Modulator Valve Assembly 1. Turn ignition key to ``ON'' and check resistance at solenoid terminals. 2. If solenoid resistance is not 51---108 ohms, replace solenoid. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Vacuum Control > Component Information > Testing and Inspection > Distributor Modulator Valve Assembly > Page 1181 Distributor Vacuum Control: Testing and Inspection Vacuum Regulator Procedure 1. Disconnect vacuum line from distributor port and connect a vacuum gauge. 2. With engine at idle, the vacuum gauge reading should be within 1 inch Hg. vacuum of the calibration point. The calibration point of each valve can be identified according to color code as follows: Black, 6 inches Hg.; green, 7 inches Hg.; red, 8 inches Hg. 3. Replace valve if not within specifications. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > Ignition Rotor - Alignment Procedure Ignition Rotor: Technical Service Bulletins Ignition Rotor - Alignment Procedure Article No. 83-8-14 EEC III/DISTRIBUTOR - PROCEDURE FOR SETTING ROTOR ALIGNMENT 5.0L/5.8L EEC EQUIPPED LIGHT TRUCKS LIGHT TRUCKS 1981/83 BRONCO, F-SERIES AND ECONOLINE The following information and procedures are issued to clarify the proper setting of distributor rotor alignment on the subject vehicles. This reference publication supersedes all other printed material on subject. FIGURE 12 FIGURE 13 For 1981 through 1983 model year vehicles, EEC distributors used on the EEC Systems had the "second generation" rotor (Figure 12). The 1983 model 5.0L EEC equipped Light Truck employs a conventional rotor (Figure 13). PROCEDURE FOR ROTOR ALIGNMENT: 1. Remove the distributor cap and wires and position them to one side. 2. Remove the rotor. 3. To check rotor alignment: a. Rotate the engine until the No. 1 piston is on the compression stroke. NOTE: Verification of being on the compression stroke is essential to correct rotor alignment. If the piston is on the exhaust stroke, the rotor can be misaligned by 180~. b. Slowly rotate the engine until the alignment tool can be installed. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > Ignition Rotor - Alignment Procedure > Page 1186 FIGURE 14 c. The T79P-12200-A tool mounts between the slot on the sleeve and the slot (cut out) on the adapter (Figure 14). d. Read the timing mark on the damper indicated by the timing pointer. e. If the timing mark is specification, TDC +/- 4~, the rotor alignment is satisfactory. The alignment tool can be removed. TO ADJUST ROTOR ALIGNMENT: 1. Remove the distributor cap by loosening the two spring clips holding the cap of the distributor adapter. Remove rotor. 2. Rotate engine until No. 1 piston is on the compression stroke. (See Step 3a above). 3. Slowly rotate the engine until the timing pointer is aligned with the specified timing mark. (TDC +/- 4~). 4. Loosen the two sleeve assembly adjustment screws and rotate the sleeve until the alignment tool T79PFIGURE 14 12200-A fits into the alignment slots on the sleeve and the adapter (Figure 14). 5. Tighten the adjustment screw to 2.8-3.9 N-m (25-30 lb.in.). Remove alignment tool. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > Ignition Rotor - Alignment Procedure > Page 1187 FIGURE 13 6. If the vehicle is a 1983 model equipped with a 5.0L engine, coat the rotor with silicone grease as shown in Figure 13. 7. Reinstall distributor cap and rotor making sure wires are firmly seated in the distributor cap terminal housings and on the spark plugs. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Distributor Plate W/ Pick-up Sensor > Component Information > Service and Repair Distributor Plate W/ Pick-up Sensor: Service and Repair 1. Remove distributor cap and rotor. 2. Remove vacuum advance unit and magnetic pickup assembly. 3. Remove attaching screws and lift base plate from distributor. 4. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Vacuum Spark Delay Valve > Component Information > Description and Operation Vacuum Spark Delay Valve: Description and Operation Fig.25 - Spark Delay Valve This unit is used in conjunction with some of the other Ford systems. Its purpose is to further reduce emissions by delaying the spark advance during rapid acceleration and by cutting off advance immediately upon deceleration. Fig. 25. This plastic disc-shaped valve is installed in the carburetor vacuum line at the distributor advance diaphragm. It is a one way valve and will not operate if installed backwards. The black side of the valve must be toward the carburetor. This valve cannot be repaired. NOTE: On all systems which employ the dual diaphragm distributor the line which has high vacuum at idle (normal operating temperature) is connected to the secondary (retard) side of the distributor vacuum advance unit. This is the connection closest to the distributor cap. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Vacuum Spark Delay Valve > Component Information > Description and Operation > Page 1194 Vacuum Spark Delay Valve: Testing and Inspection Fig.36 - SDV Valve Color Coding Fig.37 - Spark Delay Valve (SDV) Specifications Chart Refer to Figs. 36 & 37 for number value by color code. NOTE: To perform the following procedure, an external vacuum source capable of maintaining a minimum constant 10 inches Hg. is required. Mono Delay Valve 1. Set external vacuum source to 10 inches Hg. and connect black side of delay valve to vacuum source. 2. Connect a vacuum gauge with a 24 inch hose to colored side of delay valve. 3. Apply 10 inches Hg. vacuum and observe time in seconds for gauge to read 0-8 inches Hg. The minimum and maximum time for gauge to read 8 inches Hg. should be as shown in Fig. 37. Dual Delay Valve 1. Set external vacuum source to 10 inches Hg. and connect vacuum gauge with a 24 inch hose to DIST nipple of delay valve. 2. Connect black side of delay valve and CARB nipple of delay valve to vacuum source. NOTE: Avoid applying vacuum to CARB nipple while applying vacuum to black side of valve. 3. Apply 10 inches Hg. of vacuum and observe time in seconds for gauge to read from 0-8 inches Hg. The minimum and maximum time for gauge to read 8 inches Hg. should be as shown in Fig. 37. Retard Delay Valve 1. Set external vacuum source to 10 inches Hg. and connect colored side of delay valve to vacuum source. 2. Connect a vacuum gauge with a 24 inch hose to white side of delay valve. 3. Apply 10 inches Hg. of vacuum and observe time in seconds for gauge to read from 0-8 inches Hg. The minimum and maximum time for gauge to read 8 inches Hg. should be as shown in Fig. 37. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications SPARK PLUGS Gap ...................................................................................................................................................... ............................................................ 0.044 in Torque ...................................................................... ............................................................................................................. 14-20 Nm (10-15 ft-lbs) Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1198 Spark Plug: Service and Repair REMOVAL - Remove the wire from each spark plug by grasping the molded boot with tool T74P-6666-A or equivalent. Twist the boot until it loosens and then pull it off the spark plug. Do not pull on the wire, as the connection may become damaged. - Any wire damaged must be replaced. Each original spark plug wire is numbered for the cylinder to which it is designated. If wires are not numbered, each wire should be numbered as to the plug from which it was removed. - Clean the area around each spark plug port with compressed air. - Using the proper size spark plug socket remove the spark plugs. INSTALLATION Check the gap on each new spark plug and set to specification. See: Specifications Cylinder Numbering And Distributor Location - Install each spark plug and tighten to 14-20 Nm (10-15 ft-lbs). - Coat the inside of each spark plug boot with silicone dielectric compound. Connect each spark plug wire to the plug from which it was removed. Be sure each wire is fully depressed on each plug and molded boot is firmly in place. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > System Diagnosis Compression Check: Testing and Inspection COMPRESSION TEST 1. Ensure oil in crankcase is of the correct viscosity and at proper level and battery is properly charged. Operate vehicle until engine is at normal operating temperature. Turn OFF ignition switch, then remove all spark plugs. 2. Set throttle plates (and choke plates, if equipped) in wide-open position. 3. Install a compression gauge such as Rotunda Compression Tester 059-00009 or equivalent in No. 1 cylinder. 4. Install an auxiliary starter switch in starting circuit. With ignition switch in the OFF position, and using auxiliary starter switch, crank engine at least five compression strokes and record highest reading. Note the approximate number of compression strokes required to obtain the highest reading. 5. Repeat test on each cylinder cranking the engine approximately the same number of compression strokes. TEST CONCLUSION 1. The indicated compression pressures are considered within specification if the lowest reading cylinder is within 75 percent of the highest. 2. If one or more cylinders read low, squirt approximately one tablespoon of heavy SAE 50 weight or equivalent engine oil on top of the pistons in the low reading cylinders. Repeat compression pressure check on these cylinders. a. If compression improves considerably, piston rings are at fault. b. If compression does not improve, valves are sticking or seating poorly. c. If two adjacent cylinders indicate low compression pressures and squirting oil on pistons does not increase compression, cause may be a cylinder head gasket leak between cylinders. Engine oil and/or coolant in cylinders could result from this problem. Compression Pressure Limit Chart NOTE: Refer to the compression pressure limit chart for pressure specifications. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications Valve Clearance: Specifications ENGINE YEAR CLEARANCE V6-232 82-83 .088-.189 V8-255 81-82 .123-.173 6-300 80-87 .125-.175 V8-302 80-87 .096-.165 V8-351M 80-81 .125 V8-351W 80-87 .123-.173 V8-400 80-82 .175 V8-460 80-87 .100-.150 On engines with hydraulic lifters, clearance specified is at valve stem tip with lifter collapsed. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 1205 Valve Clearance: Locations FRONT TO REAR 6-300 E-I-E-I-E-I-E-I-E-I-E-I V6-232 Right I-E-I-E-I-E V6-232 Left E-I-E-I-E-I V8-255, 302 Left Bank E-I-E-I-E-I-E-I V8-255, 302 Right Bank I-E-I-E-I-E-I-E V8-351, 400 Right Bank I-E-I-E-I-E-I-E V8-351, 400 Left Bank E-I-E-I-E-I-E-I V8-460 Left Bank E-I-E-I-E-I-E-I V8-460 Right Bank I-E-I-E-I-E-I-E Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Specifications > Page 1206 Valve Clearance: Adjustments Fig. 21 Compressing valve lifter with tool to check clearance on engines with hydraulic valve lifters V8 ENGINES To provide a means to compensate for dimensional changes in the valve train and provide for valve adjustment, .060 inch shorter or longer pushrods are available. If the valve clearance is less than the minimum, the .060 inch shorter pushrod should be used. If the clearance is more than the maximum, the longer pushrod should be used. To check the valve clearance, proceed as follows: 1. Mark crankshaft pulley at three locations, with No. 1 location at TDC timing mark (end of compression stroke), location No. 2 one full turn (360°) clockwise from TDC and No. 3 location one quarter turn clockwise (90°) from position No. 2. 2. Turn crankshaft to number 1 location, then compress valve lifter using tool T71P-6513-A or equivalent, Fig. 21, and check the clearance on the following valves: V8-255, 302, 460 No. 1 Intake No. 1 Exhaust No. 7 Intake No. 5 Exhaust No. 8 Intake No. 4 Exhaust V8-351 & 400 No. 1 Intake No. 1 Exhaust No. 4 Intake No. 3 Exhaust No. 8 Intake No. 7 Exhaust 3. Turn crankshaft to number 2 location, then compress valve lifter using tool T71P-6513-A or equivalent, Fig. 21, and check the clearance on the following valves: V8-255, 302, 460 No. 5 Intake No. 2 Exhaust No. 4 Intake No. 6 Exhaust V8-351 & 400 No. 3 Intake No. 2 Exhaust No. 7 Intake No. 6 Exhaust 4. Turn crankshaft to number 3 location, then compress valve lifter using tool T71P-6513-A or equivalent, Fig. 21, and check the clearance on the following valves: V8-255, 302, 460 No. 2 Intake No. 7 Exhaust No. 3 Intake No. 3 Exhaust No. 6 Intake No. 8 Exhaust V8-351 & 400 No. 2 Intake No. 4 Exhaust No. 5 Intake No. 5 Exhaust No. 6 Intake No. 8 Exhaust Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications TEMPERATURE SENSORS Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 1211 Intake Air Temperature Sensor: Description and Operation DESCRIPTION This sensor is used on models with fuel injection. It sends air temperature information to the Electronic Control Unit to make changes for air temperature variations. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Component Testing Intake Air Temperature Sensor: Testing and Inspection Component Testing NOTE: Prior to performing any test on this system, insure that temperature switch is above 65° F. 1. Disconnect connector from wiring harness. 2. Connect an ohmmeter or self-powered test light to temperature switch connector terminals. 3. Cool the switch to below 40° F by spraying with Refrigerant 12. CAUTION: Do not spray refrigerant with engine running, as any refrigerant drawn into the carburetor and burned in the engine will produce poisonous phosgene gas. Conduct this procedure in well ventilated area. 4. When switch is cooled below 40° F. a. On type 1 switches, the internal switch contacts should open. The ohmmeter should read maximum resistance or the test light should be off. If switch does not open below 40° F, replace switch. b. On type 2 switches, the internal switch contacts should close. The ohmmeter should read zero resistance and the test light should be on. If test light does not go on or ohmmeter indicates a resistance of 1 ohm or more, replace switch. 5. Increase switch temperature to above 70° F by placing palm of hand on metal surface of switch or by starting engine and allowing the exhaust manifold heat to increase the intake air temperature. 6. When switch temperature is above 70° F. a. On type 1 switches, the internal switch contacts should close. The ohmmeter should read zero resistance and the test light should be on. If test light does not go on or ohmmeter indicates a resistance of 1 ohm or more, replace switch. b. On type 2 switches, the internal switch contacts should open. The ohmmeter should read maximum resistance or the test light should be off. If switch does not open, replace switch. c. If switch is replaced, check operation of new switch before connecting harness connector. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor > Component Information > Specifications MANIFOLD ABSOLUTE AND BAROMETRIC PRESSURE SENSORS Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor > Component Information > Specifications > Page 1217 Barometric Pressure Sensor: Locations In Engine Compartment On RH Fender Apron Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor > Component Information > Specifications > Page 1218 Barometric Pressure Sensor: Description and Operation Fig. 5 Barometric & manifold absolute pressure sensor These two sensors, Fig. 5, are combined into one unit. The BMAP sensor monitors the absolute value of the intake manifold pressure and atmospheric pressure (manifold absolute pressure is defined as barometric pressure minus manifold vacuum). Atmospheric pressure changes are converted into an electrical signal and fed to the computer for evaluation. From this input, the computer determines the EGR flow requirements depending on the altitude at which the vehicle is being operated. Intake manifold pressure changes are converted by a pressure-sensing element and electrical circuit by the computer. The signal is used by the computer to determine part throttle spark advance, EGR flow rate and air/fuel ratio. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor > Component Information > Testing and Inspection > Barometric Pressure Sensor Barometric Pressure Sensor: Testing and Inspection Barometric Pressure Sensor 1. Disconnect switch from ignition module. 2. Connect suitable ohmmeter across switch terminals and compare resistance measured to values in chart. 3. Replace switch if resistance is not within specifications. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications TEMPERATURE SENSORS Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1224 Coolant Temperature Sensor/Switch (For Computer): Locations RH Side Of V8-302/5. Near Front Of RH Valve Cover Applicable to: 0L & V8-351/5.8L w/EEC Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1225 Coolant Temperature Sensor/Switch (For Computer): Description and Operation This sensor incorporates a thermistor in a brass housing with an integral wiring connector extending from the body. This sensor is installed in the heater outlet fitting of the intake manifold. The thermistor is a resistor whose resistance value is high at low temperatures and decreases as the temperature rises. The computer applies a voltage to the sensor and monitors the resultant voltage drop across the thermistor. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications CRANKSHAFT SENSOR Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 1229 Crankshaft Position Sensor: Locations RH Front Of Engine Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 1230 Crankshaft Position Sensor: Description and Operation Fig.6 - Crankshaft Position Sensor Fig.7 - Crankshaft Position Sensor DESCRIPTION The crankshaft vibration damper is fitted with a four-lobe "pulse ring" which provides the system with an accurate indication of when the pistons reach 10 BTDC. This indication is called the reference timing. Figs. 6 and 7. The pulse ring is a powdered metal ring positioned on the crankshaft vibration damper during manufacture. It has four equally spaced lobes which represent crankshaft position when the pistons reach 10 BTDC. During operation, the lobes on the pulse ring pass by the tip of the CP sensor. The pulse ring interrupts the magnetic field at the tip of the sensor. When the field is interrupted, an output signal is generated and sent to the ECA. As the crankshaft turns, the ECA evaluates the electrical impulses to determine the exact position of the crankshaft at any given time. By the frequency of the impulses, the ECA can determine the engine speed. With these two factors, the ECA will determine the appropriate ignition timing advance required for best engine operation. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Backpressure Transducer > Component Information > Description and Operation EGR Backpressure Transducer: Description and Operation Fig.49 - Integral EGR Valve Exhaust Back-pressure Transducer This valve, Fig. 49, performs the same function as the non-integral back pressure transducer used on some systems. The valve assembly has an internal exhaust gas chamber with a transducer diaphragm which senses exhaust back pressure through a hollow stem. When back pressure is low, vacuum is bled through the transducer valve and the EGR valve stem remains closed. When back pressure increases, the transducer diaphragm moves up and closes the transducer valve vacuum bleed hole. With the vacuum bleed closed, the EGR valve opens, allowing exhaust gas to flow into the intake manifold. Because the EGR outlet is always exposed to manifold vacuum and EGR gas inlet flow is restricted by an orifice, back pressure at the transducer drops when the EGR valve opens. When the back pressure drops, the vacuum bleed hole opens, closing the EGR valve and allowing pressure to build up again. The cycle is continually repeated, modulating the flow of exhaust gas into the intake manifold. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Locations EGR Valve Position Sensor: Locations LH Side Of V8-302/5. At Center Engine To Rear Of Carburetor Applicable to: 0L Engine Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Locations > Page 1237 EGR Valve Position Sensor: Description and Operation Fig. 6 EGR valve position sensor This sensor, Fig. 6, is used to monitor the EGR valve pintle position. The computer applies a reference voltage to the EVP sensor, and the resulting signal from the EVP sensor is proportional to the amount of exhaust gases flowing through the EGR valve pintle into the intake manifold. Depending on the input from this and other sensors, the computer can increase or decrease EGR flow by activating or deactivating a pair of solenoid vacuum valves. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations Engine Control Module: Locations LH Rear Of Engine Compartment LH Fender Apron Near Ignition Module Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 1241 Engine Control Module: Description and Operation Fig. 7 Processor & calibration assembly The Electronic Control Assembly (ECA), Fig. 7, is the brain of the system. It is a solid state pre-programmed micro-computer which consists of a processor assembly and a calibration assembly, Fig. 7. The processor assembly contains the electronic circuitry which performs the following functions within a fraction of a second: a. Choose one of the sensor inputs for evaluation. b. Converts the input to a form usable by the computer to use that signal for calculations. c. Choose the proper operating strategy necessary for the operating conditions. d. Perform spark, EGR, air/fuel ratio, canister purge, throttle kicker and other calculations. e. Send electrical output control signals to the ignition module and control solenoids to adjust timing and dwell, EGR flow rate, thermactor air mode and throttle kicker mode. The processor assembly also contains a separate power supply which provides a continuous reference voltage of about 9 volts nominal to the sensors. The calibration assembly, Fig. 7, contains electronic circuitry which provides calibration equations necessary for specific vehicle application for use by the processor assembly, and provides adjustments for octane problems. The calibration assembly is mounted on the processor assembly. The power relay supplies battery voltage to the EEC system and is mounted on the right hand side of the ECA mounting bracket. It also protects the ECA from possible damage due to reversed polarity. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Feedback Control Solenoid > Component Information > Specifications MIXTURE CONTROL SOLENOID - CARBURETTED ENGINES Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Feedback Control Solenoid > Component Information > Specifications > Page 1245 Feedback Control Solenoid: Description and Operation Fig.23 - Feedback Carburetor Actuator This actuator, Fig. 23, is used to control the carburetor air/fuel ratio. The ECA uses inputs from sensors such as the exhaust gas oxygen, barometric pressure, etc., to calculate the correct signals to maintain a desired air/fuel ratio. The FBCA is a stepper motor mounted on the right side of the 7200 carburetor. The FBCA has four separate armature windings, and each one is sequentially energized by the ECA in order to obtain the necessary control of the carburetor metering rods. The motor varies the position of the metering valve in the carburetor to regulate the amount of control vacuum exposed to the fuel bowl. The vacuum lowers the amount of pressure in the fuel bowl causing a leaner air fuel mixture. During engine cranking and immediately after the engine starts, the ECA will set the FBCA at a calibration dependent upon initial position. The FBCA position is dependent upon ECA calculations of various engine sensor inputs. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Mechanical > Idle Speed Vacuum Solenoid Valve > Component Information > Locations > Throttle Kicker Vacuum Valve Idle Speed Vacuum Solenoid Valve: Locations Throttle Kicker Vacuum Valve RH Side Of V8-460/7. Top Of 8 Cyl. Engine, LH Side of 6 Cyl. Engine Applicable to: 5L Engine Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Mechanical > Idle Speed Vacuum Solenoid Valve > Component Information > Locations > Throttle Kicker Vacuum Valve > Page 1251 Idle Speed Vacuum Solenoid Valve: Locations Throttle Kicker Solenoid LH Side Of 6-300/4. Attached to LH Valve Cover Applicable to: 9L Engine Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Description and Operation Knock Sensor: Description and Operation Knock Sensor The knock sensor, Fig. 11, is a piezo-electric accelerator accelerometer with the sensor designed to resonate at approximately the same frequency as the engine knock frequency.. The sensor uses the resonant frequency to mechanically amplify the engine knock frequency (5-6 KHz). This method allows relatively large signals to be achieved without electrical amplification. The sensor has a thin circular piezoelectric ceramic disk which is bonded to a metal diaphragm. Electrical connections are made through a two-pin integral connector. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Testing and Inspection > Component Testing Knock Sensor: Testing and Inspection Component Testing Fig.8 - MCU System Wiring Circuit 1. Make sure that the following three steps are properly conducted in order to simulate spark knock conditions and determine that spark detection system is inoperative. If not, repeat test to verify problem. a. Make sure that engine is at normal operating temperature. Run engine at 2000 rpm for 2 minutes, then turn key off. Immediately restart engine and allow to idle. b. Observe voltmeter and vacuum gauge for initialization pulses after restarting the engine. The throttle kicker will also extend (increase engine speed) and remain on throughout the test. c. On vehicles with spark knock sensor, when initial pulses occur, immediately simulate spark knock by placing a 3/8 inch extension on manifold near base of knock sensor. Tap end of extension with a small hammer for about 15 seconds. 2. Disconnect jumper wire from self-test trigger input circuit 201. 3. With ignition key off, disconnect vehicle harness from spark knock sensor. 4. Using a torque wrench and a 1 1/8 inch deep socket, make sure that spark sensor is torqued to 12-18 ft. lbs. If sensor is properly torqued, proceed to next step. If not, torque to specifications. 5. Disconnect vehicle harness from MCU and spark sensor. Connect one lead of an ohmmeter to circuit 310 of vehicle harness and other lead to engine block, Fig. 8. If resistance is 1000 ohms or more, proceed to next step. If resistance is less than 1000 ohms, repair short to ground in circuit 301. 6. With key off and knock sensor harness disconnected, check circuit 310 of vehicle harness for continuity. If resistance is 10 ohms or less, continue to next step. If resistance is greater than 10 ohms, repair circuit 310. 7. Check circuit 60 of vehicle harness for continuity between knock sensor and MCU, Fig. 8. If resistance is 10 ohms or less, reconnect harness connector to MCU and proceed to next step. If resistance is greater than 10 ohms, service circuit 60. 8. Reconnect jumper wire to circuits 201 and 60 of VIP connector, Fig. 8. 9. Connect a test lamp to positive terminal of battery, then disconnect knock sensor from vehicle harness. 10. Perform "Engine Running Functional Test" procedure. When the four initialization pulses occur, continuously tap circuit 310 of the vehicle harness connector, which mates to the knock sensor connector, with the probe end for 5 seconds while observing voltmeter pulses. If a code 25 is Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Testing and Inspection > Component Testing > Page 1257 observed, replace MCU. If any other code is observed, replace spark knock sensor. SPARK KNOCK, ONLY AT WIDE OPEN THROTTLE AND/OR POOR PERFORMANCE/MILEAGE 1. If engine has a spark knock sensor, disconnect it. 2. Make sure that ignition timing is within specifications. 3. With engine running at normal operating temperature, disconnect the two wire ignition module connector (yellow wire is circuit 324 and black/white wire is circuit 69) from vehicle harness. Using a jumper wire, jump the wires together at the ignition module and note ignition timing. Remove jumper wire and note ignition timing. If timing retards 16-20 degrees, reconnect ignition module and proceed to next step. If timing does not retard 16-20 degrees, replace ignition module and repeat steps 1, 2 and 3. 4. With engine at normal operating temperature, set high cam on lowest step that will maintain engine speed greater than 1200 rpm. Note ignition timing, then disconnect and plug vacuum hose from zone vacuum switch and again note timing. If timing retards more than 5 degrees, on engines with spark knock sensor, proceed to step 6, on all other engines MCU system is okay. If timing does not retard more than 5 degrees, proceed to next step. 5. With engine still at 1200 rpm, disconnect ignition module (connector with yellow and black/white wires). If timing retards, check circuit 324 for short to ground. If circuit is okay, replace MCU unit and retest. If timing does not retard, check circuit 324 for open circuit. If circuit is okay, Replace MCU unit and retest. 6. On engines with spark knock sensor, reconnect sensor. Repeat Engine Running Functional Test, but do not simulate knock by taping sensor. If service code 25 appears, MCU system is okay, testing is completed. If any other service code appears, replace knock sensor and retest. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations RH Fender Apron w/EEC Attached To Top Of RH Fender Apron Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications MANIFOLD ABSOLUTE AND BAROMETRIC PRESSURE SENSORS Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 1264 Manifold Pressure/Vacuum Sensor: Locations RH Fender Apron w/EEC In Engine Compartment On RH Fender Apron Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 1265 Manifold Pressure/Vacuum Sensor: Description and Operation Fig. 5 Barometric & manifold absolute pressure sensor DESCRIPTION These two sensors, Fig. 5, are combined into one unit. The BMAP sensor monitors the absolute value of the intake manifold pressure and atmospheric pressure (manifold absolute pressure is defined as barometric pressure minus manifold vacuum). Atmospheric pressure changes are converted into an electrical signal and fed to the computer for evaluation. From this input, the computer determines the EGR flow requirements depending on the altitude at which the vehicle is being operated. Intake manifold pressure changes are converted by a pressure-sensing element and electrical circuit by the computer. The signal is used by the computer to determine part throttle spark advance, EGR flow rate and air/fuel ratio. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Gas Oxygen (EGO) Sensor <--> [Oxygen Sensor] > Component Information > Locations Exhaust Gas Oxygen (EGO) Sensor: Locations RH Side Of V8-302/5. On Exhaust Manifold RH Side Of Engine Applicable to: 0L & V8-351/5.8L w/EEC Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Exhaust Gas Oxygen (EGO) Sensor <--> [Oxygen Sensor] > Component Information > Locations > Page 1269 Exhaust Gas Oxygen (EGO) Sensor: Description and Operation Fig. 4 Exhaust gas oxygen sensor This sensor, Fig. 4, is installed in the exhaust manifold and provides information to the ECA as to the oxygen content of the exhaust gases. It monitors the oxygen content of the exhaust gases and generates an output of .6 to 1.0 volt when detecting a rich exhaust gas mixture (absence of oxygen) and less than .2 volts when detecting a lean mixture (presence of oxygen). This constantly changing voltage signal is sent to the ECA for analysis. The outer surface of the sensor is a threaded steel housing and shell. The sensor body is protected by a shield pressed into the housing where it projects into the exhaust manifold. Exhaust gases contact the sensor body by entering through flutes in the sensor shield. A vent is provided in the shell to allow atmospheric air to enter the inner portion of the sensor body. The sensor connects to the vehicle wiring harness with a connector that is attached to the inner (positive) terminal. The shell is the negative terminal of the sensor and provides the return signal path through the engine block. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations Engine Control Module: Locations LH Rear Of Engine Compartment LH Fender Apron Near Ignition Module Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Locations > Page 1274 Engine Control Module: Description and Operation Fig. 7 Processor & calibration assembly The Electronic Control Assembly (ECA), Fig. 7, is the brain of the system. It is a solid state pre-programmed micro-computer which consists of a processor assembly and a calibration assembly, Fig. 7. The processor assembly contains the electronic circuitry which performs the following functions within a fraction of a second: a. Choose one of the sensor inputs for evaluation. b. Converts the input to a form usable by the computer to use that signal for calculations. c. Choose the proper operating strategy necessary for the operating conditions. d. Perform spark, EGR, air/fuel ratio, canister purge, throttle kicker and other calculations. e. Send electrical output control signals to the ignition module and control solenoids to adjust timing and dwell, EGR flow rate, thermactor air mode and throttle kicker mode. The processor assembly also contains a separate power supply which provides a continuous reference voltage of about 9 volts nominal to the sensors. The calibration assembly, Fig. 7, contains electronic circuitry which provides calibration equations necessary for specific vehicle application for use by the processor assembly, and provides adjustments for octane problems. The calibration assembly is mounted on the processor assembly. The power relay supplies battery voltage to the EEC system and is mounted on the right hand side of the ECA mounting bracket. It also protects the ECA from possible damage due to reversed polarity. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations RH Fender Apron w/EEC Attached To Top Of RH Fender Apron Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Sensor > Component Information > Specifications MANIFOLD ABSOLUTE AND BAROMETRIC PRESSURE SENSORS Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Sensor > Component Information > Specifications > Page 1282 Barometric Pressure Sensor: Locations In Engine Compartment On RH Fender Apron Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Sensor > Component Information > Specifications > Page 1283 Barometric Pressure Sensor: Description and Operation Fig. 5 Barometric & manifold absolute pressure sensor These two sensors, Fig. 5, are combined into one unit. The BMAP sensor monitors the absolute value of the intake manifold pressure and atmospheric pressure (manifold absolute pressure is defined as barometric pressure minus manifold vacuum). Atmospheric pressure changes are converted into an electrical signal and fed to the computer for evaluation. From this input, the computer determines the EGR flow requirements depending on the altitude at which the vehicle is being operated. Intake manifold pressure changes are converted by a pressure-sensing element and electrical circuit by the computer. The signal is used by the computer to determine part throttle spark advance, EGR flow rate and air/fuel ratio. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Sensor > Component Information > Testing and Inspection > Barometric Pressure Sensor Barometric Pressure Sensor: Testing and Inspection Barometric Pressure Sensor 1. Disconnect switch from ignition module. 2. Connect suitable ohmmeter across switch terminals and compare resistance measured to values in chart. 3. Replace switch if resistance is not within specifications. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications TEMPERATURE SENSORS Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1289 Coolant Temperature Sensor/Switch (For Computer): Locations RH Side Of V8-302/5. Near Front Of RH Valve Cover Applicable to: 0L & V8-351/5.8L w/EEC Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 1290 Coolant Temperature Sensor/Switch (For Computer): Description and Operation This sensor incorporates a thermistor in a brass housing with an integral wiring connector extending from the body. This sensor is installed in the heater outlet fitting of the intake manifold. The thermistor is a resistor whose resistance value is high at low temperatures and decreases as the temperature rises. The computer applies a voltage to the sensor and monitors the resultant voltage drop across the thermistor. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications CRANKSHAFT SENSOR Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 1294 Crankshaft Position Sensor: Locations RH Front Of Engine Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 1295 Crankshaft Position Sensor: Description and Operation Fig.6 - Crankshaft Position Sensor Fig.7 - Crankshaft Position Sensor DESCRIPTION The crankshaft vibration damper is fitted with a four-lobe "pulse ring" which provides the system with an accurate indication of when the pistons reach 10 BTDC. This indication is called the reference timing. Figs. 6 and 7. The pulse ring is a powdered metal ring positioned on the crankshaft vibration damper during manufacture. It has four equally spaced lobes which represent crankshaft position when the pistons reach 10 BTDC. During operation, the lobes on the pulse ring pass by the tip of the CP sensor. The pulse ring interrupts the magnetic field at the tip of the sensor. When the field is interrupted, an output signal is generated and sent to the ECA. As the crankshaft turns, the ECA evaluates the electrical impulses to determine the exact position of the crankshaft at any given time. By the frequency of the impulses, the ECA can determine the engine speed. With these two factors, the ECA will determine the appropriate ignition timing advance required for best engine operation. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Locations EGR Valve Position Sensor: Locations LH Side Of V8-302/5. At Center Engine To Rear Of Carburetor Applicable to: 0L Engine Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Locations > Page 1299 EGR Valve Position Sensor: Description and Operation Fig. 6 EGR valve position sensor This sensor, Fig. 6, is used to monitor the EGR valve pintle position. The computer applies a reference voltage to the EVP sensor, and the resulting signal from the EVP sensor is proportional to the amount of exhaust gases flowing through the EGR valve pintle into the intake manifold. Depending on the input from this and other sensors, the computer can increase or decrease EGR flow by activating or deactivating a pair of solenoid vacuum valves. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications TEMPERATURE SENSORS Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 1303 Intake Air Temperature Sensor: Description and Operation DESCRIPTION This sensor is used on models with fuel injection. It sends air temperature information to the Electronic Control Unit to make changes for air temperature variations. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Testing and Inspection > Component Testing Intake Air Temperature Sensor: Testing and Inspection Component Testing NOTE: Prior to performing any test on this system, insure that temperature switch is above 65° F. 1. Disconnect connector from wiring harness. 2. Connect an ohmmeter or self-powered test light to temperature switch connector terminals. 3. Cool the switch to below 40° F by spraying with Refrigerant 12. CAUTION: Do not spray refrigerant with engine running, as any refrigerant drawn into the carburetor and burned in the engine will produce poisonous phosgene gas. Conduct this procedure in well ventilated area. 4. When switch is cooled below 40° F. a. On type 1 switches, the internal switch contacts should open. The ohmmeter should read maximum resistance or the test light should be off. If switch does not open below 40° F, replace switch. b. On type 2 switches, the internal switch contacts should close. The ohmmeter should read zero resistance and the test light should be on. If test light does not go on or ohmmeter indicates a resistance of 1 ohm or more, replace switch. 5. Increase switch temperature to above 70° F by placing palm of hand on metal surface of switch or by starting engine and allowing the exhaust manifold heat to increase the intake air temperature. 6. When switch temperature is above 70° F. a. On type 1 switches, the internal switch contacts should close. The ohmmeter should read zero resistance and the test light should be on. If test light does not go on or ohmmeter indicates a resistance of 1 ohm or more, replace switch. b. On type 2 switches, the internal switch contacts should open. The ohmmeter should read maximum resistance or the test light should be off. If switch does not open, replace switch. c. If switch is replaced, check operation of new switch before connecting harness connector. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Description and Operation Knock Sensor: Description and Operation Knock Sensor The knock sensor, Fig. 11, is a piezo-electric accelerator accelerometer with the sensor designed to resonate at approximately the same frequency as the engine knock frequency.. The sensor uses the resonant frequency to mechanically amplify the engine knock frequency (5-6 KHz). This method allows relatively large signals to be achieved without electrical amplification. The sensor has a thin circular piezoelectric ceramic disk which is bonded to a metal diaphragm. Electrical connections are made through a two-pin integral connector. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Testing and Inspection > Component Testing Knock Sensor: Testing and Inspection Component Testing Fig.8 - MCU System Wiring Circuit 1. Make sure that the following three steps are properly conducted in order to simulate spark knock conditions and determine that spark detection system is inoperative. If not, repeat test to verify problem. a. Make sure that engine is at normal operating temperature. Run engine at 2000 rpm for 2 minutes, then turn key off. Immediately restart engine and allow to idle. b. Observe voltmeter and vacuum gauge for initialization pulses after restarting the engine. The throttle kicker will also extend (increase engine speed) and remain on throughout the test. c. On vehicles with spark knock sensor, when initial pulses occur, immediately simulate spark knock by placing a 3/8 inch extension on manifold near base of knock sensor. Tap end of extension with a small hammer for about 15 seconds. 2. Disconnect jumper wire from self-test trigger input circuit 201. 3. With ignition key off, disconnect vehicle harness from spark knock sensor. 4. Using a torque wrench and a 1 1/8 inch deep socket, make sure that spark sensor is torqued to 12-18 ft. lbs. If sensor is properly torqued, proceed to next step. If not, torque to specifications. 5. Disconnect vehicle harness from MCU and spark sensor. Connect one lead of an ohmmeter to circuit 310 of vehicle harness and other lead to engine block, Fig. 8. If resistance is 1000 ohms or more, proceed to next step. If resistance is less than 1000 ohms, repair short to ground in circuit 301. 6. With key off and knock sensor harness disconnected, check circuit 310 of vehicle harness for continuity. If resistance is 10 ohms or less, continue to next step. If resistance is greater than 10 ohms, repair circuit 310. 7. Check circuit 60 of vehicle harness for continuity between knock sensor and MCU, Fig. 8. If resistance is 10 ohms or less, reconnect harness connector to MCU and proceed to next step. If resistance is greater than 10 ohms, service circuit 60. 8. Reconnect jumper wire to circuits 201 and 60 of VIP connector, Fig. 8. 9. Connect a test lamp to positive terminal of battery, then disconnect knock sensor from vehicle harness. 10. Perform "Engine Running Functional Test" procedure. When the four initialization pulses occur, continuously tap circuit 310 of the vehicle harness connector, which mates to the knock sensor connector, with the probe end for 5 seconds while observing voltmeter pulses. If a code 25 is Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Testing and Inspection > Component Testing > Page 1311 observed, replace MCU. If any other code is observed, replace spark knock sensor. SPARK KNOCK, ONLY AT WIDE OPEN THROTTLE AND/OR POOR PERFORMANCE/MILEAGE 1. If engine has a spark knock sensor, disconnect it. 2. Make sure that ignition timing is within specifications. 3. With engine running at normal operating temperature, disconnect the two wire ignition module connector (yellow wire is circuit 324 and black/white wire is circuit 69) from vehicle harness. Using a jumper wire, jump the wires together at the ignition module and note ignition timing. Remove jumper wire and note ignition timing. If timing retards 16-20 degrees, reconnect ignition module and proceed to next step. If timing does not retard 16-20 degrees, replace ignition module and repeat steps 1, 2 and 3. 4. With engine at normal operating temperature, set high cam on lowest step that will maintain engine speed greater than 1200 rpm. Note ignition timing, then disconnect and plug vacuum hose from zone vacuum switch and again note timing. If timing retards more than 5 degrees, on engines with spark knock sensor, proceed to step 6, on all other engines MCU system is okay. If timing does not retard more than 5 degrees, proceed to next step. 5. With engine still at 1200 rpm, disconnect ignition module (connector with yellow and black/white wires). If timing retards, check circuit 324 for short to ground. If circuit is okay, replace MCU unit and retest. If timing does not retard, check circuit 324 for open circuit. If circuit is okay, Replace MCU unit and retest. 6. On engines with spark knock sensor, reconnect sensor. Repeat Engine Running Functional Test, but do not simulate knock by taping sensor. If service code 25 appears, MCU system is okay, testing is completed. If any other service code appears, replace knock sensor and retest. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications MANIFOLD ABSOLUTE AND BAROMETRIC PRESSURE SENSORS Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 1315 Manifold Pressure/Vacuum Sensor: Locations RH Fender Apron w/EEC In Engine Compartment On RH Fender Apron Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page 1316 Manifold Pressure/Vacuum Sensor: Description and Operation Fig. 5 Barometric & manifold absolute pressure sensor DESCRIPTION These two sensors, Fig. 5, are combined into one unit. The BMAP sensor monitors the absolute value of the intake manifold pressure and atmospheric pressure (manifold absolute pressure is defined as barometric pressure minus manifold vacuum). Atmospheric pressure changes are converted into an electrical signal and fed to the computer for evaluation. From this input, the computer determines the EGR flow requirements depending on the altitude at which the vehicle is being operated. Intake manifold pressure changes are converted by a pressure-sensing element and electrical circuit by the computer. The signal is used by the computer to determine part throttle spark advance, EGR flow rate and air/fuel ratio. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Gas Oxygen (EGO) Sensor <--> [Oxygen Sensor] > Component Information > Locations Exhaust Gas Oxygen (EGO) Sensor: Locations RH Side Of V8-302/5. On Exhaust Manifold RH Side Of Engine Applicable to: 0L & V8-351/5.8L w/EEC Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Exhaust Gas Oxygen (EGO) Sensor <--> [Oxygen Sensor] > Component Information > Locations > Page 1320 Exhaust Gas Oxygen (EGO) Sensor: Description and Operation Fig. 4 Exhaust gas oxygen sensor This sensor, Fig. 4, is installed in the exhaust manifold and provides information to the ECA as to the oxygen content of the exhaust gases. It monitors the oxygen content of the exhaust gases and generates an output of .6 to 1.0 volt when detecting a rich exhaust gas mixture (absence of oxygen) and less than .2 volts when detecting a lean mixture (presence of oxygen). This constantly changing voltage signal is sent to the ECA for analysis. The outer surface of the sensor is a threaded steel housing and shell. The sensor body is protected by a shield pressed into the housing where it projects into the exhaust manifold. Exhaust gases contact the sensor body by entering through flutes in the sensor shield. A vent is provided in the shell to allow atmospheric air to enter the inner portion of the sensor body. The sensor connects to the vehicle wiring harness with a connector that is attached to the inner (positive) terminal. The shell is the negative terminal of the sensor and provides the return signal path through the engine block. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications THROTTLE POSITION SENSOR SPECIFICATIONS Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 1324 Throttle Position Sensor: Description and Operation Fig. 2 Throttle position sensor (typical) This sensor, Fig. 2, is basically a rheostat switch attached to the carburetor throttle shaft and responds to throttle valve angle changes. The throttle angles are classified into three operating modes as follows: a. Closed Throttle (Idle or Deceleration) b. Part Throttle c. Wide Open Throttle (Maximum Acceleration) The ECA applies a reference voltage of about 9 volts to the sensor. The resultant sensor voltage supplied to the ECA, which is determined by the throttle position, is used by the ECA to determine the proper amount of spark advance, EGR flow, air/fuel ratio and thermactor air mode. The throttle position sensor mounting holes are slotted to permit adjustment. If the sensor is replaced, it must be correctly positioned or incorrect throttle information will be sent to the ECA. The adjustment requires use of special electronic test equipment. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 1325 Throttle Position Sensor: Adjustments Engines with EEC III Turn ignition to RUN position and remove vacuum hose from throttle kicker, as equipped. With engine not running, compare voltage reading against specifications and adjust as needed. Engines with EEC IV Connect positive probe of DVOM along terminal C (lower) of TPS and connect negative probe along terminal A (upper). Turn ignition on but do not start vehicle. Adjust TPS to specified value. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations At LH Side Of Dash Panel Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Speed Sensor Test Vehicle Speed Sensor: Testing and Inspection Speed Sensor Test 1980-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986-87 Aerostar 1. Disconnect 6 way connector from amplifier assembly, then connect an ohmmeter between dark green wire w/white stripe and black wire on 1980 E-100-350, 1981-83 F-100-350 models and Bronco, and 1984-87 F-150-350 and Bronco, or green and black wire on 1980 F-100-350 and 1981-83 E-100-350 models and 1984-87 E-150-350 at the speed sensor end. A reading of 40 ohms should be obtained. A reading of 0 ohms indicates a shorted coil and an infinity reading indicates an open coil. 2. Replace sensor if a correct reading has not been obtained. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Page 1331 Vehicle Speed Sensor: Service and Repair 1. Separate electrical connector leading to the amplifier assembly. 2. Disconnect upper and lower speedometer cables at the speed sensor. Remove speed sensor. 3. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications THROTTLE POSITION SENSOR SPECIFICATIONS Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 1335 Throttle Position Sensor: Description and Operation Fig. 2 Throttle position sensor (typical) This sensor, Fig. 2, is basically a rheostat switch attached to the carburetor throttle shaft and responds to throttle valve angle changes. The throttle angles are classified into three operating modes as follows: a. Closed Throttle (Idle or Deceleration) b. Part Throttle c. Wide Open Throttle (Maximum Acceleration) The ECA applies a reference voltage of about 9 volts to the sensor. The resultant sensor voltage supplied to the ECA, which is determined by the throttle position, is used by the ECA to determine the proper amount of spark advance, EGR flow, air/fuel ratio and thermactor air mode. The throttle position sensor mounting holes are slotted to permit adjustment. If the sensor is replaced, it must be correctly positioned or incorrect throttle information will be sent to the ECA. The adjustment requires use of special electronic test equipment. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 1336 Throttle Position Sensor: Adjustments Engines with EEC III Turn ignition to RUN position and remove vacuum hose from throttle kicker, as equipped. With engine not running, compare voltage reading against specifications and adjust as needed. Engines with EEC IV Connect positive probe of DVOM along terminal C (lower) of TPS and connect negative probe along terminal A (upper). Turn ignition on but do not start vehicle. Adjust TPS to specified value. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Vehicle Speed Sensor: Locations At LH Side Of Dash Panel Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Speed Sensor Test Vehicle Speed Sensor: Testing and Inspection Speed Sensor Test 1980-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986-87 Aerostar 1. Disconnect 6 way connector from amplifier assembly, then connect an ohmmeter between dark green wire w/white stripe and black wire on 1980 E-100-350, 1981-83 F-100-350 models and Bronco, and 1984-87 F-150-350 and Bronco, or green and black wire on 1980 F-100-350 and 1981-83 E-100-350 models and 1984-87 E-150-350 at the speed sensor end. A reading of 40 ohms should be obtained. A reading of 0 ohms indicates a shorted coil and an infinity reading indicates an open coil. 2. Replace sensor if a correct reading has not been obtained. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Testing and Inspection > Page 1342 Vehicle Speed Sensor: Service and Repair 1. Separate electrical connector leading to the amplifier assembly. 2. Disconnect upper and lower speedometer cables at the speed sensor. Remove speed sensor. 3. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Solenoid > Component Information > Locations Air Diverter Solenoid: Locations At RH Of Vacuum Switch On Valve Cover Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Valve > Component Information > Description and Operation Air Diverter Valve: Description and Operation Fig.71 - Air Pump Mounted Timed Air Bypass Valve Fig.72 - Timed Air Bypass Valve Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Valve > Component Information > Description and Operation > Page 1351 Fig.73 - Normally Closed Timed Air Bypass Valve Fig.74 - Timed Air Bypass Valve With Integral Function DESCRIPTION Some 1966-67 vehicles use a bypass type anti-backfire valve in place of the "gulp" type system. The valve operates at all times and all output air from the air pump is routed through it. The air flow to the manifolds is temporarily interrupted and diverted to the air pump air cleaner during deceleration. The air bypass system on 1968-82 vehicles serves the same purpose as earlier types, but three different types of bypass valves are used, depending on application. These are: a timed bypass valve, a normally closed bypass valve, or a timed bypass valve with an integral vacuum function. They are mounted "in-line," or on the air pump. Figs. 71, 72, 73, and 74. On systems using a timed bypass valve, Figs. 71 and 72, during normal operation, vacuum is equalized on both sides of the diaphragm. The diaphragm return spring holds the valve closed, and allows air to flow to the exhaust ports. During deceleration, the sudden rise of intake manifold vacuum under the diaphragm overcomes return spring pressure and pulls the valve down. The air flow is then momentarily diverted to atmosphere, because vacuum is quickly equalized again on both sides of the diaphragm through a small orifice in the diaphragm. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Valve > Component Information > Description and Operation > Page 1352 The normally closed timed bypass valve, Fig. 73, is used on vehicles with catalytic converter. During normal operation, engine manifold vacuum applied through the vacuum differential valve (VDV) holds the valve upward, allowing thermactor air to flow to the exhaust manifolds and blocking the vent port. When intake manifold vacuum rises or drops sharply, the VDV operates and momentarily cuts off the vacuum to the bypass valve. The spring pulls the stem down, seating the valve to cut off pump air to the exhaust manifolds and dumping the dump valve to momentarily divert the air to atmosphere. If air pump pressure becomes excessive or there is a restriction in the system, the excess pressure will unseat the valve in the lower portion of the bypass valve and allow a partial flow of pump air to the atmosphere, while at the same time, the valve in the upper part of the bypass is still unseated, allowing a partial flow of pump air to the exhaust manifold to meet system requirements. The timed air bypass valve with an integral vacuum differential function, Fig. 74, is used on some thermactor systems. This valve contains an integral vacuum differential function, therefore a separate vacuum differential valve (VLV) is not required. When the vent is blocked, the valve functions as a timed bypass valve with a VDV. However, when the vent is open to atmospheric pressure, and a vacuum of 4 inches Hg or more is applied to the source port, the valve goes to the dump mode. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Valve > Component Information > Testing and Inspection > Normally Closed (Type 1) Solenoid Vacuum Valve Air Diverter Valve: Testing and Inspection Normally Closed (Type 1) Solenoid Vacuum Valve Note: A type 1 solenoid vacuum valve is used in conjunction with a type 1 air cleaner temperature switch. Procedure: 1. Start engine and allow to reach normal operating temperature. Make sure that ambient air around air cleaner is above 65° F. 2. With engine idling, disconnect vacuum hose to thermactor air bypass valve. Thermactor air should exhaust in atmosphere through exhaust ports in end of valve silencer cover. Reconnect vacuum hose. NOTE: Vacuum supply hose must always be connected to bottom vacuum fitting on solenoid vacuum valve. 3. Disconnect vacuum supply hose at solenoid valve, and check for vacuum by placing finger over end of hose. There should be vacuum with engine idling. If not, check vacuum hose and vacuum source for leaks or obstructions. 4. Disconnect solenoid vacuum valve wiring connector and determine which terminal has 12 volts with ignition in the run position. Use a test light; connect one end to terminal and other end to ground. 5. Connect wire with 12 volts battery voltage to solenoid vacuum valve. With engine idling, ground other exposed terminal on solenoid vacuum valve to chassis ground. Thermactor air should not be dumped. 6. Reconnect wire disconnected in step 4 to solenoid vacuum valve. Thermactor air should not be dumped. 7. Replace solenoid vacuum valve if operation is not as specified in steps 5 and 6. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Valve > Component Information > Testing and Inspection > Normally Closed (Type 1) Solenoid Vacuum Valve > Page 1355 Air Diverter Valve: Testing and Inspection Normally Open (Type 2) Solenoid Vacuum Valve Note: A type 2 solenoid vacuum valve is used in conjunction with a type 2 air cleaner temperature switch. Procedure 1. Start engine and allow to reach normal operating temperature. Make sure that ambient air around air cleaner is above 65° F. 2. With engine idling, disconnect vacuum hose to thermactor air bypass valve. Thermactor air should exhaust to atmosphere through exhaust ports in end of valve silencer cover. Reconnect vacuum hose. NOTE: Vacuum hose must be connected to black input nozzle on solenoid valve. 3. Disconnect wiring to solenoid valve and determine which wire has 12 volts when ignition switch is in the run position. Use a test light; connect one end to wire and other end to ground. 4. Connect wire power supply wire to solenoid vacuum valve, then with engine at normal idle, ground other exposed terminal on solenoid vacuum valve to ground. Thermactor air should be exhausted to atmosphere. 5. Reconnect other wire to solenoid vacuum valve. Thermactor air should not be dumped to atmosphere. 6. Replace solenoid vacuum valve if operation is not as specified in steps 4 and 5. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Bypass Valve > Component Information > Technical Service Bulletins > Customer Interest for Air Injection Bypass Valve: > 832321 > Nov > 83 > Thermactor Air Bypass Valve - Hissing/Moaning Noise Air Injection Bypass Valve: Customer Interest Thermactor Air Bypass Valve - Hissing/Moaning Noise Article No. 83-23-21 NOISE - EMISSION CONTROL, THERMACTOR AIR BYPASS VALVE - (3.8L, 5.0L, AND 5.8L) MANUAL TRANSMISSION VEHICLES WITH 3.8L OR 5.0L ENGINES AND ANY 5.8L VEHICLE OVER 8500 LB. GVW LIGHT TRUCKS 1982/83 E & F SERIES Under certain conditions, a "hissing" or "moan" noise may be audible in the passenger compartment of the subject vehicles. This noise may be emanating from the Air Bypass Valve during normal venting of thermactor air to the atmosphere. The following procedure should minimize this concern: 1. Accurately define customer concern. 2. For vehicles equipped with thermactor bypass valve (Part No. E1TE-9B289-DA or DB) discard and replace with thermactor bypass valve (Part No. E3TZ-9B289-G) and ensure valve is oriented in same position as original. 3. For vehicles equipped with thermactor bypass valve (Part No. E3TE-9B289-BA or BB) discard and replace with thermactor bypass valve (Part No. E3TZ-9B289-H) and ensure valve is oriented in same position as original. 4. Road test vehicle to ensure the condition has been eliminated. Obtain an Authorized Modifications decal and list the date, dealer number and summary of alterations performed. Select a prominent place adjacent to the Vehicle Emission Control Information decal suitable for installing the Authorized Modifications decal. Clean the area, install the decal and cover it with a clear plastic decal shield. PART NUMBER PART NAME CLASS E3TZ-9B289-G Air Bypass Valve B E3TZ-9B289-H Air Bypass Valve B OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION/TIME: Refer to the Labor Time Standards Manual for applicable operation and time. DLR. CODING: Basic Part No. 9B289 Code: 56 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Bypass Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Injection Bypass Valve: > 832321 > Nov > 83 > Thermactor Air Bypass Valve - Hissing/Moaning Noise Air Injection Bypass Valve: All Technical Service Bulletins Thermactor Air Bypass Valve Hissing/Moaning Noise Article No. 83-23-21 NOISE - EMISSION CONTROL, THERMACTOR AIR BYPASS VALVE - (3.8L, 5.0L, AND 5.8L) MANUAL TRANSMISSION VEHICLES WITH 3.8L OR 5.0L ENGINES AND ANY 5.8L VEHICLE OVER 8500 LB. GVW LIGHT TRUCKS 1982/83 E & F SERIES Under certain conditions, a "hissing" or "moan" noise may be audible in the passenger compartment of the subject vehicles. This noise may be emanating from the Air Bypass Valve during normal venting of thermactor air to the atmosphere. The following procedure should minimize this concern: 1. Accurately define customer concern. 2. For vehicles equipped with thermactor bypass valve (Part No. E1TE-9B289-DA or DB) discard and replace with thermactor bypass valve (Part No. E3TZ-9B289-G) and ensure valve is oriented in same position as original. 3. For vehicles equipped with thermactor bypass valve (Part No. E3TE-9B289-BA or BB) discard and replace with thermactor bypass valve (Part No. E3TZ-9B289-H) and ensure valve is oriented in same position as original. 4. Road test vehicle to ensure the condition has been eliminated. Obtain an Authorized Modifications decal and list the date, dealer number and summary of alterations performed. Select a prominent place adjacent to the Vehicle Emission Control Information decal suitable for installing the Authorized Modifications decal. Clean the area, install the decal and cover it with a clear plastic decal shield. PART NUMBER PART NAME CLASS E3TZ-9B289-G Air Bypass Valve B E3TZ-9B289-H Air Bypass Valve B OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION/TIME: Refer to the Labor Time Standards Manual for applicable operation and time. DLR. CODING: Basic Part No. 9B289 Code: 56 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Bypass Valve > Component Information > Technical Service Bulletins > Page 1369 Air Injection Bypass Valve: Description and Operation Normally closed timed air bypass valve. Normally open timed air bypass valve with vacuum vent. Normally open timed air bypass valve less vacuum vent. The air bypass system serves the same purpose as earlier types, but three different types of bypass valves are used, depending on application. These are: normally closed bypass valve, normally open bypass valve with vacuum vent and normally open bypass valve without vacuum vent. They are mounted "inline", or on the air pump, Figs. 85, 86 and 87. The normally closed timed bypass valve, Fig. 85, is used on vehicles with catalytic converter. During normal operation, engine manifold vacuum applied through the vacuum differential valve (VDV) holds the valve upward, allowing thermactor air to flow to the exhaust manifolds and blocking the vent port. When intake manifold vacuum rises or drops sharply, the VDV operates and momentarily cuts off the vacuum to the bypass valve. The spring Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Bypass Valve > Component Information > Technical Service Bulletins > Page 1370 pulls the stem down, seating the valve to cut off pump air to the exhaust manifolds and dumping the dump valve to momentarily divert the air to atmosphere. If air pump pressure becomes excessive or there is a restriction in the system, the excess pressure will unseat the valve in the lower portion of the bypass valve and allow a partial flow of pump air the atmosphere, while at the same time, the valve in the upper part of the bypass is still unseated, allowing a partial flow of pump air to the exhaust manifold to meet system requirements. The normally open timed bypass valve with vacuum vents, Fig. 86, provides a timed air dump during deceleration and when differences in vacuum pressure between the signal port and vent port occur. The signal port must have 3 inches Hg more vacuum than the vent port to prevent the valve from dumping. The valve is used to protect catalyst overheating. The normally open timed bypass valve without vacuum vents supplies air to the exhaust system with a higher than normal vacuum signal during cold start, short idles is applied, pump air is dumped through the silencer ports of the valve, Fig. 87. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Bypass Valve > Component Information > Technical Service Bulletins > Page 1371 Air Injection Bypass Valve: Testing and Inspection Normally Closed 1. Disconnect air supply hose at valve outlet, then remove vacuum line and check if vacuum is present at vacuum nipple. 2. Remove any restrictors or delay valves in vacuum line. Before proceeding to step 3, ensure vacuum is present at vacuum nipple. 3. Reconnect vacuum line to nipple, then accelerate engine to 1500 RPM. 4. Air pump supply should be present at air bypass valve outlet. Disconnect vacuum line, air at outlet should stop and air pump supply air should be present at silencer port. 5. If above step proves incorrect, check air pump, then bypass valve. Normally Open With Vacuum Vents 1. Disconnect air pump supply line at outlet, then vacuum lines from vacuum nipple and vacuum vent. 2. Accelerate engine to 1500 RPM, air pump supply air should be present at outlet. 3. Using suitable vacuum hose, connect vacuum nipple to intake manifold vacuum. No air should be present at valve outlet, all air should bypass through silencer ports. 4. Using the same vacuum hose as above step, cap vacuum vent and accelerate engine to 2000 RPM. Air pump supply air should be interrupted when throttle is released. 5. If above steps prove incorrect, check air pump, then bypass valve. Normally Open Without Vacuum Vent 1. Disconnect air supply line at valve outlet, then vacuum line at vacuum nipple. 2. Accelerate engine to 1500 RPM, air pump supply air should be present at outlet. 3. Using suitable vacuum hose, connect vacuum nipple to intake manifold vacuum. Air at outlet should decrease or shut off. 4. Air pump supply air should be present at silencer ports. 5. If above steps prove incorrect, check air pump, then bypass valve. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Check Valve > Component Information > Description and Operation Air Injection Check Valve: Description and Operation This valve, used on some vehicles, allows thermactor air to enter exhaust port drillings, but prevents reverse flow of exhaust gases in event of improper operation of system components. This valve is located between bypass valve and exhaust port drillings, either on air manifold or engine. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Check Valve > Component Information > Description and Operation > Page 1375 Air Injection Check Valve: Testing and Inspection 1. Check valves should be inspected whenever the hose is disconnected from the valve or check valve failure is suspected. NOTE: Any indication of exhaust gases in the air pump indicates check valve failure. 2. Orally blow through the check valve (toward air manifold) then attempt to suck back. Flow should be toward air manifold only. 3. When replacing a check valve, be careful not to bend or twist the air manifold. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Check Valve > Component Information > Description and Operation > Page 1376 Air Injection Check Valve: Service and Repair PROCEDURE 1. Disconnect air supply valve from hose and, using a 1 1/4 inch crow-foot wrench, remove check valve. 2. Clean threads on air manifold adapter using a wire brush, then install new check valve. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve > Component Information > Description and Operation > Air Supply Control Valves Air Injection Control Valve: Description and Operation Air Supply Control Valves Fig.75 - Standard Air Control Valve Fig.76 - Air Control & Shut Off Valve Fig.77 - Air Control & Shut Off Valve With Orifice Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve > Component Information > Description and Operation > Air Supply Control Valves > Page 1381 DESCRIPTION These valves are used to direct air pump output to the exhaust manifold or downstream to the catalyst system depending on the engine control modes. Three types of valves are used, the standard air control valve, Fig. 75, the air control/shut off valve with orifice, Fig. 76, and the air control/shut off valve, Fig. 77. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve > Component Information > Description and Operation > Air Supply Control Valves > Page 1382 Air Injection Control Valve: Description and Operation Combination Air Bypass/Air Control Valves Fig. 70 Normally open combination air bypass/air control valve less bleed Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve > Component Information > Description and Operation > Air Supply Control Valves > Page 1383 Fig. 71 Normally closed combination air bypass/air control valve less bleed Fig. 72 Normally closed combination air bypass/air control valve with bleed These valves, used on some 1982---87 vehicles, combine the function of the air bypass valve and the air control valve. Three types of valves are used, a normally open valve, Fig. 70, a normally closed valve without bleed, Fig. 71, and a normally closed valve with bleed, Fig. 72. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve > Component Information > Description and Operation > Air Supply Control Valves > Page 1384 Air Injection Control Valve: Description and Operation Thermactor Vacuum Vent Valve Fig. 76 Thermactor vacuum vent valve Fig. 77 Thermactor vacuum vent valve schematic (typical) This valve, Figs. 76 and 77, is used on some engines equipped with variable venturi carburetor. It provides the air for the thermactor retard delay valve and air bypass valve during idle modes to deactivate the thermactor system after a controlled period of time. Application of vacuum from the carburetor to both ports of the thermactor vacuum vent causes the dump valve to seat and vacuum to be applied to the rest of the system. Removal Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve > Component Information > Description and Operation > Air Supply Control Valves > Page 1385 of vacuum during idle modes results in unseating of the dump valve, opening of the vent and allowing air to enter the system to reduce the vacuum previously applied to the retard delay valve. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve > Component Information > Description and Operation > Air Supply Control Valves > Page 1386 Air Injection Control Valve: Description and Operation Vacuum Differential Valve (VDV) Fig. 78 Vacuum Differential Valve (VDV) On some vehicles with the Thermactor system and catalytic converters, a VDV, Fig. 78, is used to control the operation of the air bypass valve. Under normal operation, vacuum applied through the VDV holds the valve upward, blocking the vent port and allowing Thermactor air flow. During acceleration or deceleration or in case of system failure, the VDV momentarily cuts off vacuum flow to the bypass valve, diverting the Thermactor air flow to atmosphere. In case of excessive pressure or system restriction, the excess pressure will unseat the valve in the lower part of the bypass valve, allowing a partial flow of air to atmosphere. At the same time, the valve in the upper part of the valve remains unseated allowing a partial flow of air to the exhaust manifold. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve > Component Information > Testing and Inspection > Air Control Valve Air Injection Control Valve: Testing and Inspection Air Control Valve Fig. 67 Standard air control valve. 1983---87 Standard Air Control Valve 1. Run engine at 1500 RPM and disconnect air supply hose at inlet, Fig. 67. There should be air flow at hose. Reconnect air supply hose at valve inlet. 2. Disconnect air supply hoses at outlets A and B and the vacuum line at the vacuum nipple. 3. Run engine at 1500 RPM. There should be air flow at outlet B but little or no air flow at outlet A. 4. Run engine at 1500 RPM and connect a direct vacuum line from any manifold vacuum fitting to air control valve vacuum nipple. There should be air flow at outlet A but little or no air flow at outlet B. 5. Connect all vacuum hoses at original positions. If valve does not function correctly, replace valve. AIR CONTROL/SHUT-OFF VALVE 1. Start engine and run at idle, disconnect vacuum supply hose from vacuum nipple, and disconnect inlet hose from valve. Suction should be felt at valve opening. 2. Apply manifold vacuum to vacuum nipple. No suction should be felt at valve inlet opening. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve > Component Information > Testing and Inspection > Air Control Valve > Page 1389 Fig. 69 Air control & shut off valve with orifice. 1983 AIR CONTROL/SHUT-OFF VALVE WITH ORIFICE 1. Disconnect valve inlet supply hose and ensure that there is air flow to valve inlet, Fig. 69, then reconnect air supply hose. 2. Run engine at 1500 RPM and disconnect air supply hose at valve outlet and the vacuum hose at vacuum nipple. There should be air flow at valve outlet. 3. Connect a direct vacuum line from any manifold fitting to valve vacuum nipple. There should be a noticeable increase in air flow at valve outlet. 4. Connect all vacuum hoses at original positions. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve > Component Information > Testing and Inspection > Air Control Valve > Page 1390 Air Injection Control Valve: Testing and Inspection Combination Air Bypass/Air Control Valves Fig. 71 Normally closed combination air bypass/air control valve less bleed Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve > Component Information > Testing and Inspection > Air Control Valve > Page 1391 Fig. 72 Normally closed combination air bypass/air control valve with bleed NORMALLY CLOSED VALVES 1. Disconnect hoses from outlets A and B, Figs. 71 and 72. 2. Disconnect and plug vacuum line to port D. 3. Run engine at 1500 RPM. There should be air flow at bypass vents. 4. Reconnect vacuum line to port D and disconnect and plug vacuum line to port S, then ensure that vacuum is present in line to vacuum port D. 5. Run engine at 1500 RPM. There should be air flow at outlet B but no air flow at outlet A. 6. Apply 8---10 inches Hg vacuum to port S and run engine at 1500 RPM. There should be air flow at outlet A. 7. On bleed type valve, some lesser amount of air will flow from outlet A or B and the main discharge will change when vacuum is applied to port S. If there is a small air tap attached to the inlet tube from the air pump, air flow should be present during engine operation. Fig. 70 Normally open combination air bypass/air control valve less bleed NORMALLY OPEN VALVES 1. Disconnect hoses from outlets A and B, Fig. 70. 2. Disconnect and plug vacuum lines to ports D and S. 3. Run engine at 1500 RPM. There should be air flow at outlet B. 4. Apply 8---10 inches Hg vacuum to port S and run engine at 1500 RPM. There should be air flow at outlet A. 5. Reconnect vacuum line to port D and ensure that vacuum is present. 6. Run engine at 1500 RPM. Air should flow out of bypass vents. 7. Reconnect vacuum hoses to original positions. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve > Component Information > Testing and Inspection > Air Control Valve > Page 1392 Air Injection Control Valve: Testing and Inspection Thermactor Vacuum Vent Valve 1. If necessary, remove air cleaner assembly. 2. Disconnect vacuum tubing or connector block from valve, noting location of tubing. It may be necessary to remove valve from bracket or air cleaner tray to gain access to vacuum ports on valve. 3. Connect the black vacuum port to a manifold vacuum source. 4. Connect an external vacuum source to white body vacuum port. 5. With engine idling in neutral, apply 10 inches Hg vacuum to white port and trap. If vacuum cannot be obtained, replace valve. 6. Remove manifold vacuum source line from black port. The trapped vacuum should drop to zero. If not, replace valve. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve > Component Information > Testing and Inspection > Air Control Valve > Page 1393 Air Injection Control Valve: Testing and Inspection Vacuum Differential Valve (VDV) 1. Start engine and allow to reach normal operating temperature with transmission in Park or Neutral and parking brake applied. 2. Stop engine and remove air bypass valve to air manifold check valve hose and bypass valve. On systems with two check valves, remove both hoses. Connect tachometer to engine. 3. Start engine, then with hand placed over bypass valve outlet connections, accelerate engine to 2500 RPM and release throttle, allowing engine to return to normal idle. During deceleration, the air flow in the valve outlet should be felt or heard to momentarily diminish or stop and then resume to normal air flow. Air flow will be discharged through the exhaust ports in the end of the bypass valve silencer cover. 4. If bypass valve does not function as described in step 3, check to make sure that decel valve is receiving a vacuum signal. If it is, the decel valve is defective and should be replaced. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Filter > Component Information > Service and Repair Air Injection Filter: Service and Repair Fig. 68 Removing centrifugal type air pump filter Centrifugal Filter Fan, Replace 1. Remove drive pulley and outer disc from air pump. 2. Remove filter fan from pump, Fig. 90. NOTE: Do not attempt to remove the metal drive hub. 3. Install new filter fan using the pulley and bolts. Alternately tighten bolts to draw fan down evenly. NOTE: A slight interference between the fan and housing is normal. A new fan may make noise during initial operation, until it's outer diameter sealing lip has worn in, after approximately 20-30 miles of operation. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Hose/Tube > Component Information > Testing and Inspection Air Injection Hose/Tube: Testing and Inspection CAUTION: The hoses used with this system are made of special material to withstand high temperature. No other type should be used. Procedure: 1. Inspect all hoses and tubes for deterioration or cracks. 2. Check hose and tube routing as interference may cause wear. 3. Check all hose and tube connections. 4. Check the pressure side of the system for leaks with a soapy water solution. With the pump running, bubbles will form if a leak exists. 5. When replacing any hose or tube, note routing before removal. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Manifold Rails <--> [Air Injection Manifold] > Component Information > Testing and Inspection Air Manifold Rails: Testing and Inspection CAUTION: The hoses used with this system are made of special material to withstand high temperature. No other type should be used. Procedure: 1. Inspect all hoses and tubes for deterioration or cracks. 2. Check hose and tube routing as interference may cause wear. 3. Check all hose and tube connections. 4. Check the pressure side of the system for leaks with a soapy water solution. With the pump running, bubbles will form if a leak exists. 5. When replacing any hose or tube, note routing before removal. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Manifold Rails <--> [Air Injection Manifold] > Component Information > Testing and Inspection > Page 1403 Air Manifold Rails: Service and Repair PROCEDURE 1. Disconnect air supply hose from check valve and position hose aside. 2. Unscrew air manifold to cylinder head coupling nuts until free of the cylinder head, then remove air manifold. 3. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Pump <--> [Air Injection Pump] > Component Information > Technical Service Bulletins > Customer Interest: > 831621 > Aug > 83 > Exhaust Air Pump - Moaning Noise Air Pump: Customer Interest Exhaust Air Pump - Moaning Noise Article No. 83-16-21 NOISE - POWERTRAIN MOAN - AT APPROXIMATELY 2,000 RPM - 5.8L UNITS LIGHT TRUCKS 1980-83 E, F AND BRONCO FIGURE 29 A drumming and/or moaning noise, at approximately 2,000 RPM, may be the result of the exhaust air pump adjustment arm flange being too wide. The flange may contact the body of the air pump preventing proper pump to bracket fit (Figure 29). Visual inspection can confirm if the condition is present. To service this condition, the following procedure is recommended: 1. Loosen alternator and air pump adjustment slot and pivot bolts. 2. Move the alternator and air pump to a position that will allow the removal of both the alternator and air pump drive belts. 3. Remove the air pump adjustment slot bolt and alternator pivot bolt from the alternator bracket, then remove the air pump adjustment arm. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Pump <--> [Air Injection Pump] > Component Information > Technical Service Bulletins > Customer Interest: > 831621 > Aug > 83 > Exhaust Air Pump - Moaning Noise > Page 1412 FIGURE 29 4. Grind .0625" (1/16 inch) off entire flange radius of air pump adjustment arm (Figure 29). Ensure there are no sharp burrs remaining. 5. Install air pump adjustment arm and install alternator and air pump drive belts by reversing procedure of steps 1 through 3. 6. Tension alternator belt 110-130 lbs. and tension air pump belt 80-100 lbs. 7. Torque bolts as follows: adjustment slot bolts (alternator and air pump); 24-34 ft.lbs. Air pump pivot bolt; 35-50 ft.lbs. Alternator pivot bolt; 45-55 ft.lbs. 8. Start engine to ensure noise has been eliminated and that all accessory drive components are positioned and functioning properly. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP9452A83 TIME: 0.4 Hr. DLR. CODING: Basic Part No. 9B452 Code: 16 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Pump <--> [Air Injection Pump] > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 93311 > Feb > 93 > Exhaust Air Pump Assembly - Obsolete Part Return Air Pump: All Technical Service Bulletins Exhaust Air Pump Assembly - Obsolete Part Return Article No. 93-3-11 February 3, 1993 SERVICE PARTS RETURN OF OBSOLETE EXHAUST AIR PUMP ASSEMBLY FORD: 1981 FAIRMONT, THUNDERBIRD LINCOLN-MERCURY: 1981 COUGAR, MONARCH LIGHT TRUCK: 1981-83 ECONOLINE 1981-86 F-150-350 SERIES 1986 BRONCO ISSUE: Exhaust Air Pump Assembly (E1TZ-9A486-D) (CX-631) may not meet Ford's high quality requirements and should be withdrawn from your inventory. This Sort and Purge of part numbers (E1TZ-9A486-D) (CX-631) which lack the threaded mounting hole should be withdrawn from your inventory and returned to your facing PDC within 30 days of this TSB. ACTION: Return the obsolete parts from your dealership's inventory. 1. Sort stock (E1TZ-9A486-D) (CX-631) which lacks the threaded mounting hole. 2. Return part numbers (E1TZ-9A486-D) (CX-631) which lack this threaded hole and return to your facing PDC using the least expensive transportation. 3. If claim is processed electronically via DOES II, use return code "GB"; otherwise, complete a separate FPS-340 claim for these parts. 4. Indicate Reason "J" on claims. 5. In the Remarks Section write "Returned per TSB 93-3-11". LIMITS ^ The returns must be received within 30 days from the date of this TSB. ^ Returns are restricted to the subject parts. ^ The parts returned must have been purchased from FPSD in accordance with Policy and Procedure Bulletin 4000. CREDIT Credit for parts and prepaid freight costs will be issued. NOTE: REPLACEMENT STOCK IS AVAILABLE FOR ORDERING IMMEDIATELY. PART NUMBER PART NAME CLASS E1TZ-9A486-D Exhaust Air Pump Assembly AM OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 403000, 623000 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Pump <--> [Air Injection Pump] > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 831621 > Aug > 83 > Exhaust Air Pump - Moaning Noise Air Pump: All Technical Service Bulletins Exhaust Air Pump - Moaning Noise Article No. 83-16-21 NOISE - POWERTRAIN MOAN - AT APPROXIMATELY 2,000 RPM - 5.8L UNITS LIGHT TRUCKS 1980-83 E, F AND BRONCO FIGURE 29 A drumming and/or moaning noise, at approximately 2,000 RPM, may be the result of the exhaust air pump adjustment arm flange being too wide. The flange may contact the body of the air pump preventing proper pump to bracket fit (Figure 29). Visual inspection can confirm if the condition is present. To service this condition, the following procedure is recommended: 1. Loosen alternator and air pump adjustment slot and pivot bolts. 2. Move the alternator and air pump to a position that will allow the removal of both the alternator and air pump drive belts. 3. Remove the air pump adjustment slot bolt and alternator pivot bolt from the alternator bracket, then remove the air pump adjustment arm. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Pump <--> [Air Injection Pump] > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 831621 > Aug > 83 > Exhaust Air Pump - Moaning Noise > Page 1422 FIGURE 29 4. Grind .0625" (1/16 inch) off entire flange radius of air pump adjustment arm (Figure 29). Ensure there are no sharp burrs remaining. 5. Install air pump adjustment arm and install alternator and air pump drive belts by reversing procedure of steps 1 through 3. 6. Tension alternator belt 110-130 lbs. and tension air pump belt 80-100 lbs. 7. Torque bolts as follows: adjustment slot bolts (alternator and air pump); 24-34 ft.lbs. Air pump pivot bolt; 35-50 ft.lbs. Alternator pivot bolt; 45-55 ft.lbs. 8. Start engine to ensure noise has been eliminated and that all accessory drive components are positioned and functioning properly. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP9452A83 TIME: 0.4 Hr. DLR. CODING: Basic Part No. 9B452 Code: 16 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Pump <--> [Air Injection Pump] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Pump: > 8871033088 > Mar > 88 > Power Door Locks - Are Inoperative Power Door Lock Actuator: All Technical Service Bulletins Power Door Locks - Are Inoperative LOCKS - POWER - ROD RETAINER CLIP ASSEMBLY BREAKS OR DISENGAGES POWER DOOR LOCKS - INOPERATIVE - ROD RETAINER CLIP BREAKS OR DISENGAGES Article No. 88-7-1 FORD: 1980-82 GRANADA 1980-83 FAIRMONT 1980-88 MUSTANG, THUNDERBIRD, CROWN VICTORIA 1983-86 LTD 1984-85 ESCORT 1984-88 TEMPO 1986-88 TAURUS LINCOLN-MERCURY: 1980 MONARCH 1980-81 LINCOLN 1980-83 ZEPHYR, MARK VI 1980-86 CAPRI 1980-88 COUGAR, GRAND MARQUIS 1982-88 CONTINENTAL, LINCOLN TOWN CAR 1983-86 MARQUIS 1984-85 LYNX 1984-88 TOPAZ, MARK VII 1986-88 SABLE MERKUR: 1985-88 XR4Ti 1988 SCORPIO LIGHT TRUCK: 1980-88 ECONOLINE 1981-88 F SERIES 1985-86 RANGER, BRONCO II ISSUE: Inoperative power door locks maybe caused by a broken or disengaged lock rod retainer clip assembly. The broken or disengaged retainer clip allows the power lock actuator to disconnect from the actuator rod. ACTION: To correct this, install a new lock rod retainer clip assembly made out of stronger material. Refer to the following removal and installation procedure. 1. Remove door trim panel and water shield. 2. Remove broken or disengaged retainer assembly and replace it with new retainer assembly (E8AZ-5421952-A). NOTE: To prevent damage, make sure the latch assembly is supported from behind before tapping the retainer assembly into the latch assembly. Be careful not to bend the lever of the latch. 3. In some cases, the latch assembly may have to be removed to provide enough space to install the retainer assembly. Refer to Section 44 of the appropriate Shop Manual for latch removal and installation procedures. 4. Reinstall water shield and door trim panel. PART NUMBER PART NAME CLASS E8AZ-5421952-A Retainer Clip Assembly BG OTHER APPLICABLE ARTICLES: 85-12-3 WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Pump <--> [Air Injection Pump] > Component Information > Technical Service Bulletins > Page 1433 Air Pump: Testing and Inspection PROCEDURE 1. Remove air cleaner, then inspect all hoses and hose connections for leaks. Correct as necessary. Check belt tension and correct as necessary. 2. With transmission in Park or Neutral with parking brake applied, start engine and allow it to reach normal operating temperature. 3. Stop engine. Disconnect air supply hose(s) from air pump to air bypass valve from pump. 4. Install Rotunda T57L-9486-A or equivalent thermactor test gauge in end of hose disconnected from bypass valve. Secure hose with clamp to prevent it from blowing out. On side or cover mounted bypass valves, install an elbow and hose adapter, then install test gauge. CAUTION: Position air pump supply tester so that air blast emitted will be harmlessly dissipated. 5. Connect tachometer to engine and start engine. Slowly increase engine speed to 1000 rpm while observing pressure at gauge. Air pump pressure should be at least 2 1/4 psi. If rotunda tool is not used, increase engine speed to 1500 rpm and place hand over open hose. Air flow should be heard and felt. 6. If air pump output pressure is not at least 2 1/4 psi, or if air flow is not heard and felt, replace pump and repeat test. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Pump <--> [Air Injection Pump] > Component Information > Service and Repair > Air Injection Pump, Replace Air Pump: Service and Repair Air Injection Pump, Replace 1. Disconnect air inlet and outlet hoses from air pump. 2. Remove drive belt and mounting bolts from pump and remove the pump. 3. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Pump <--> [Air Injection Pump] > Component Information > Service and Repair > Air Injection Pump, Replace > Page 1436 Air Pump: Service and Repair Air Pump Relief Valve, Replace NOTE: The air pump does not have to be disassembled to replace the relief valve; however, it must be removed from the engine. PROCEDURE 1. Install Tool T66L-9A486-D on air pump and remove relief valve using a suitable slide hammer. 2. To install relief valve, use Tool T66L- 9A4S6-B and lightly hammer the valve until it is seated. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Pump <--> [Air Injection Pump] > Component Information > Service and Repair > Air Injection Pump, Replace > Page 1437 Air Pump: Service and Repair Relief Valve Pressure Setting Plug, Replace PROCEDURE 1. Compress shoulders of pressure setting plug together and pull plug out of relief valve. 2. Install new valve into relief valve hole by pressing against its center with a suitable tool. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Pulsed Secondary Air Injection > Component Information > Description and Operation Pulsed Secondary Air Injection: Description and Operation Fig. 79 Thermactor II system (typical) Fig. 80 Thermactor II pulse air valve operation Some engines are equipped with this type of exhaust air injection system, Fig. 79, which does not have an air pump. The system uses the natural pulses of the exhaust system to draw air into the exhaust manifold. The system is regulated by a pulse air valve. The valve, Fig. 80, is connected to the air cleaner with a hose and to the exhaust manifold with a metal tube. Some pulse air valves closely resemble the standard Thermactor check valves, but are not interchangeable with them. When pressure inside the exhaust manifold is more than the pressure in the air cleaner, the reed in the pulse air valve is closed. When pressure in the exhaust manifold is lower than in the air cleaner, the reed opens and allows air to be drawn into the exhaust manifold. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Thermal Vacuum Valve, Air Injection > Component Information > Description and Operation Thermal Vacuum Valve: Description and Operation Fig. 27 Temperature vacuum switch--TVS This switch, Fig. 27, used on some vehicles, has a bimetal disc which locates itself in one of two positions, depending on its temperature. One position allows free air flow in the vacuum line; and the other blocks air flow by sealing itself against the O-ring. The switching temperature is below the range of normal engine operating temperature. The TVS may be used to control the vacuum signal to the thermactor dump valve, to reduce emissions. The normally open TVS may block the purge vacuum signal to provide satisfactory cold driveability and reduce cold engine emissions. It may be also used to hold off EGR operation during cold engine operation. The normally closed TVS may allow cold spark advance to provide satisfactory cold engine driveability. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Thermal Vacuum Valve, Air Injection > Component Information > Testing and Inspection > Electric PVS High Temp Coolant Lock Out Vacuum Thermal Vacuum Valve: Testing and Inspection Electric PVS High Temp Coolant Lock Out Vacuum 1975-82 Vehicles With Catalytic Converter 1. Disconnect vacuum line from air bypass valve to PVS valve at air bypass valve and connect to vacuum gauge. 2. With transmission in Park or Neutral and parking brake applied, start engine and allow to idle. 3. With engine at normal operating temperature, there should be a vacuum reading. If not, PVS is defective and should be replaced. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Thermal Vacuum Valve, Air Injection > Component Information > Testing and Inspection > Electric PVS High Temp Coolant Lock Out Vacuum > Page 1446 Thermal Vacuum Valve: Testing and Inspection Temperature Vacuum Switch (TVS) 1982-83 1. Apply 16 inches Hg to motor side of valve and trap. Cool to test temperature. Switch should hold vacuum as follows: a. White TVS--normally open. At 40° F must hold 5 inches Hg for 30 seconds. Should not hold vacuum above 80° F. b. Brown TVS--normally open. At 5° F must hold 5 inches Hg for 30 seconds. Should not hold vacuum above 40° F. c. Purple TVS--normally open. At 30° F must hold 5 inches for 30 seconds. Should not hold vacuum above 60° F. d. Red TVS--normally closed. At 80° F or higher must hold 5 inches Hg for 30 seconds. Should not hold vacuum below 40° F. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Thermal Vacuum Valve, Air Injection > Component Information > Testing and Inspection > Electric PVS High Temp Coolant Lock Out Vacuum > Page 1447 Thermal Vacuum Valve: Testing and Inspection Thermactor PVS (With 2 Connectors) PROCEDURE 1. Disconnect both vacuum hoses at PVS valve. Connect vacuum gauge to bottom connector on PVS. 2. Using an external vacuum source, apply at least 10 inches Hg vacuum to top connector. With engine cold, there should be no vacuum reading. If there is, replace PVS. 3. Start engine and allow to reach normal operating temperature. With 10 inches Hg vacuum applied, there should be a vacuum reading. If not, PVS is defective and should be replaced. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Vacuum Check Valve, AIR > Component Information > Description and Operation > Thermactor Vacuum Vent Valve Vacuum Check Valve: Description and Operation Thermactor Vacuum Vent Valve Fig.86 - Thermactor Vacuum Vent Valve Fig.87 - Thermactor Vacuum Vent Valve Schematic DESCRIPTION This valve, Figs. 86 and 87, is used on some 1978-82 engines equipped with variable venturi carburetor. It provides the air for the thermactor retard delay valve and air bypass valve during idle modes to deactivate the thermactor system after a controlled period of time. Application of vacuum from the carburetor to both ports of the thermactor vacuum vent causes the dump valve to seat and vacuum to be applied to the rest of the system. Removal of vacuum during idle modes results in unseating of the dump valve, opening of the vent and allowing air to enter the system to reduce the vacuum previously applied to the retard delay valve. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Vacuum Check Valve, AIR > Component Information > Description and Operation > Thermactor Vacuum Vent Valve > Page 1452 Vacuum Check Valve: Description and Operation Vacuum Check Valve Vacuum Check Valve The vacuum check valve , Fig. 31, blocks air flow in one direction. It allows free air flow in the other direction. The check side of this valve will hold the highest vacuum on the vacuum side. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Vacuum Check Valve, AIR > Component Information > Testing and Inspection > Thermactor Vacuum Vent Valve Vacuum Check Valve: Testing and Inspection Thermactor Vacuum Vent Valve PROCEDURE 1. If necessary, remove air cleaner assembly. 2. Disconnect vacuum tubing or connector block from valve, noting location of tubing. NOTE: It may be necessary to remove valve from bracket or air cleaner tray to gain access to vacuum ports on valve. 3. Connect the black vacuum port to a manifold vacuum source. 4. Connect an external vacuum source to white body vacuum port. 5. With engine idling in neutral, apply 10 inches Hg vacuum to white port and trap. If vacuum cannot be obtained, replace valve. 6. Remove manifold vacuum source line from black port. The trapped vacuum should drop to zero. If not, replace valve. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Vacuum Check Valve, AIR > Component Information > Testing and Inspection > Thermactor Vacuum Vent Valve > Page 1455 Vacuum Check Valve: Testing and Inspection Vacuum Check Valve To check vacuum check valve, use a suitable hand held vacuum pump and apply 16 inches Hg vacuum to the check portion of valve. Maintain vacuum. If vacuum applied remains above 15 inches Hg vacuum for approximately 10 seconds, the vacuum check valve is operating properly. If not, replace vacuum check valve. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Vacuum Check Valve, AIR > Component Information > Testing and Inspection > Thermactor Vacuum Vent Valve > Page 1456 Vacuum Check Valve: Testing and Inspection Vacuum Reservoir Check Valve NOTE: This valve is used on some vehicles equipped with catalytic converter. PROCEDURE 1. Disconnect vacuum hose on reservoir which connects to electric solenoid valve vacuum nipple. 2. Connect a 0-30 inch Hg vacuum gauge to reservoir using a suitable length of hose. 3. Disconnect manifold vacuum hose from reservoir and connect an external vacuum source to the nipple. Apply 14 inches Hg vacuum to reservoir and trap. Vacuum reading on gauge should not drop more than 1 inch Hg in one minute. If it does, replace reservoir. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Dual Catalytic Converter Catalytic Converter: Description and Operation Dual Catalytic Converter Fig. 17 Dual catalytic converter This converter consists of two catalytic converters in one shell, with a mixing chamber in between the two, Fig. 17. Each converter is composed of a ceramic ``honey comb'' coated with a rhodium/platinum catalyst designed to control oxides of nitrogen (NOx), unburned hydrocarbons (HC) and carbon monoxide (CO), and is therefore called a ``three way catalyst'' (TWC). The rear converter is coated with platinum catalyst and is called a ``conventional'' oxidation catalyst'' (COC) converter. The platinum catalyst is also called a ``two way catalyst'' since it only acts on two of the major pollutants, HC and CO. The TWC converter acts on the exhaust gases from the engine. As the gases flow from the TWC to the COC converter, they mix with air from the thermactor pump injected into the mixing chamber or ``mid-bed''. This air is required for proper oxidation of HC and CO in the COC converter. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Dual Catalytic Converter > Page 1461 Catalytic Converter: Description and Operation General Description Fig.8 - Catalytic Converter With Single Substrate Catalyst Fig.9 - Catalytic Converter With Dual Substrate Catalyst The catalytic converter is an emission control device added to the exhaust system to effectively reduce the levels of carbon monoxide (CO), hydrocarbons (HC), and in some cases oxides of nitrogen (NOx), entering the atmosphere. The converter permits a faster chemical reaction to take place and although it enters into the chemical reaction, it remains unchanged, ready to repeat the process. The catalyst in these converters is structured in the form of a honeycomb monolithic composition, Figs. 8 and 9. The catalyst consists of a porous substrate of an inert material, coated with platinum and other noble metals (the catalytically active materials). NOTE: Phase II Catalytic Converters or Dual Catalytic Converters which also control the NOx emissions, are used on some 1978-82 vehicles. During engine operation, all of the exhaust gases flow through the converter where a chemical change takes place. This change causes the temperature inside the converter to be higher than the temperature of the exhaust gases when they leave the engine. Due to this increase in heat, the converter is insulated so that its outside temperature is about the same temperature as the muffler. However, due to its solid mass, the converter remains hot much longer than the muffler. The body of the catalytic converter is made of stainless steel designed to last the life of the vehicle. Excessive heat can bulge or distort the converter. Since excessive heat built up is not the fault of the converter, the carburetion or ignition system should be checked whenever a converter is damaged by overheating. Although all vehicles with catalytic converter must use unleaded fuel, small amounts of leaded fuel can be used in case of an emergency. To prevent adding leaded fuel, the fuel tank filler nozzle has a built-in restrictor. Heat shields are used on some vehicles to protect chassis components, passenger compartment, and other areas from heat damage that may be caused by the catalytic converter. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 1462 Catalytic Converter: Testing and Inspection Blocked or restricted exhaust system usually results in lack of power or popping through the intake system. Verify that this condition is not caused by ignition timing problems, then proceed with diagnosis. Catalyst and Exhaust Systems Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Description and Operation > Page 1463 Catalyst and Exhaust Systems Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Early Fuel Evaporation ( EFE ) > Exhaust Heat Control Valve <--> [EFE Valve] > Component Information > Specifications > Mechanical Specifications Exhaust Heat Control Valve: Mechanical Specifications PVS Body Color Opening Temperature Black 92-98 F Blue 125-131 F Purple 157-163 F Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Early Fuel Evaporation ( EFE ) > Exhaust Heat Control Valve <--> [EFE Valve] > Component Information > Specifications > Mechanical Specifications > Page 1469 Exhaust Heat Control Valve: Pressure, Vacuum and Temperature Specifications PVS Body Color Opening Temperature Black 92-98 F Blue 125-131 F Purple 157-163 F Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Early Fuel Evaporation ( EFE ) > Exhaust Heat Control Valve <--> [EFE Valve] > Component Information > Specifications > Page 1470 Exhaust Heat Control Valve: Description and Operation Fig. 16 Exhaust heat control valve--HCV Used on some V8 engines, this system, Fig. 16, provides quick induction system warm-up for better cold engine fuel vaporization. A vacuum operated heat control valve mounted between the exhaust manifold and pipe, directs a portion of the exhaust gases through the intake manifold during engine warm-up. On cold starts, manifold vacuum is directed to the heat control valve (HCV) through the top two ports in HCV PVS (ported vacuum switch), closing the HCV. When engine coolant temperature reaches a predetermined value, the PVS closes off vacuum and vents the PVS allowing the HCV to close under spring tension. The three PVS valves used may be identified as follows: Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Bowl Vent Solenoid > Component Information > Description and Operation Bowl Vent Solenoid: Description and Operation Fig. 9 Carburetor fuel bowl solenoid vent valve This valve, Fig. 9, used on some vehicles, is a normally open valve located in the fuel bowl vent line to the carbon canister. When the engine is running, the valve closes off the fuel bowl vent line. When the engine is shut off, the vent line returns to the normally open condition. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Bowl Vent Solenoid > Component Information > Description and Operation > Page 1475 Bowl Vent Solenoid: Testing and Inspection Apply 12 volts to valve. The valve should close, allowing no air to pass. NOTE: If a lean fuel mixture is suspected of causing a problem, inspect either the solenoid vent valve or the fuel bowl vent valve for proper closing during engine operation. If the valve opens, allowing purged vacuum to affect fuel bowl balanced air pressure, the carburetor will give a leaner air/fuel mixture. On EEC equipped engines with a 7200 VV feedback carburetor (back-suction type only), the opposite (rich mixture) will result from an open or leaking valve. CAUTION: The utmost care should be exercised when using a torch in the area of the fuel evaporation system as an open flame near these hoses may cause a fire and ultimate explosion. NOTE: Vapor line hoses used in these systems are made from a special rubber material. Bulk service hoses are available for service and will be marked "EVAP". Ordinary fuel hoses should not be used. They are subject to deterioration and may clog system. CAUTION: Installation of a fill cap from a non-emission fuel tank will render the system inoperative, since the non-emission fill cap is vented and the system must be sealed to function properly. Also if a non-vented fill cap is installed on a conventional tank, the result will be a serious deformation or a total collapse of the fuel tank. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Bowl Vent Valve > Component Information > Description and Operation Bowl Vent Valve: Description and Operation Fig. 10 Carburetor fuel bowl thermal vent valve The thermal vent valve, Fig. 10, used on some vehicles, is a temperature actuated on/off valve, that is inserted in the carburetor to carbon canister vent line. This valve is closed when the engine compartment is cold, preventing fuel tank vapors, generated when the fuel tank heats up before the engine compartment, from being vented through the carburetor bowl. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Bowl Vent Valve > Component Information > Description and Operation > Page 1479 Bowl Vent Valve: Testing and Inspection 1. With ambient temperature at or below 90° F, ensure that valve is fully closed. 2. With ambient temperature at or above 120° F, ensure that valve is fully open. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Description and Operation Canister Purge Control Valve: Description and Operation Fig.55 - Purge Control Valve DESCRIPTION This valve, Fig. 55, is installed on the carbon canister and controls the flow of fuel vapors during various engine operating modes. The control is provided by a vacuum signal from either the spark port, EGR port or intake manifold and opens or closes the valve accordingly. When the engine is off, the vapors from the fuel tank and carburetor fuel bowl are routed through the purge control valve and into the carbon canister for storage. During normal cruise conditions, spark port or EGR vacuum is strong enough to open the orifice in the purge control valve to allow fuel vapors to flow from the carburetor canister through the purge line to a connection in the PCV tube or into the carburetor spacer. At the same time, the vapors from the fuel tank are also directed into the purge line. At idle and low speed cruise conditions, spark port or EGR port vacuum is not strong enough to open the orifice in the purge control valve so that the fuel vapors are then routed to the carbon canister. NOTE: On some vehicles fuel vapors are not purged during low engine speeds because the additional fuel vapors will affect the fuel air mixture, resulting in a reduction of idle quality and an increase in exhaust emissions. On vehicles not affected by this purging, manifold vacuum is used to actuate the purge control valve and control the purging of fuel vapors since spark port or EGR port vacuum is too weak. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Description and Operation > Page 1483 Canister Purge Control Valve: Testing and Inspection Fig.63 - Purge Control Valves Apply 16 inches Hg vacuum to port A. Air should pass between ports B and C. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Description and Operation Canister Purge Solenoid: Description and Operation Fig. 52 Canister purge solenoid This valve, Fig. 52, used on some vehicles, controls the flow of vapors from the carbon canister to the intake manifold during various engine operating modes. This is a normally closed valve that is opened by a signal from the electronic engine control assembly to control carbon canister purging. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Air Separator > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Emissions Air Separator: > 831112S > Sep > 84 > Fuel System - Stalls/No Start/Hesitation/ Stumble Evaporative Emissions Air Separator: Customer Interest Fuel System - Stalls/No Start/Hesitation/ Stumble Article No. 83-11-12-S STALLS/NO START/HESITATION/ STUMBLE - VAPOR LOCK (5.8L, 6.6L 7.5L) - VEHICLES OVER 8500 LBS. GVW LIGHT TRUCKS 1980/82 E250/350, F250/350 The service part numbers for kits "D" and "E" have been changed from E2UZ-9350-B to E0UZ-9350-D (Kit D) and E2UZ-9350-C to E0UZ-9350-C (Kit E) in TSB 83-11-12. The TSB Article is being reprinted showing the correct part numbers. NOTE: This TSB replaces TSB 82-14-21 dated July 16, 1982 in its entirety. DO NOT attempt to use TSB 82-14-21 to order service parts. Loss of road speed, hesitation, or engine stall on the subject vehicles operated at ambient temperatures over 85~F or at elevations over 4,500 feet, may be the result of fuel vaporization. A modification kit is available for vehicles experiencing this condition. It consists of an in-tank fuel pump, inertia shut-off switch, motorized fuel selector valve, vapor separator, and a vapor return system, along with related fuel lines and electrical wiring and devices. Before this modification is considered, other factors that could result in the same symptoms should be evaluated. Some of these include: ^ Plugged fuel filter at carburetor or tank. ^ Restricted fuel line. ^ Contaminated or low quality fuel. ^ Malfunctioning fuel pump or carburetor. If it is determined that the above factors have not caused the customer concern then the appropriate modification kit should be used to change the fuel system. Hardware Required: Components required to modify the vehicle differ with vehicle series, engine model and type of fuel tank. These have been packaged into 13 different kits. The chart that follows describes the specific kits that are required for the various vehicle configurations. Continued on next page TANK ENGINE (CID) KITS REQUIRED F-Series Single (Midship) 351M/400 A, F, H Single (Plastic Aft Axle) 351M/400 F, C, L Single (Metal Aft Axle) 351M/400 B, F, L Dual (Steel Aft Axle) 351M/400 A, B, F, I Dual (Plastic Aft Axle) 351M/400 A, C, F, I E-Series Single (Aft Axle) 351M/400 D, F, J Dual 351M/400 D, E, F, K E-Series Single (Aft Axle) 7.5L 460 D, G, J Dual 7.5L 460 D, E, G, K KIT SERVICE PART NO. DESCRIPTION CLASS A E2TZ-9350-D Fuel Pump/Sender Kit CG B E2TZ-9350-F Fuel Pump/Sender Kit CG C E2TZ-9350-C Fuel Pump/Sender Kit CG D E0UZ-9350-D Fuel Pump/Sender Kit CG E E0UZ-9350-C Fuel Pump/Sender Kit CG F E0TZ-9B328-A Vapor Separator Kit CG G E0TZ-9B328-B Vapor Separator Kit CG H E2TZ-9A350-H Fuel Line/Electrical Kit CG I E2TZ-9A350-F Fuel Line/Electrical Kit CG J E2UZ-9A350-F Fuel Line/Electrical Kit CG K E2UZ-9A350-D Fuel Line/Electrical Kit CG L E2TZ-9350-G Fuel Line/Electrical Kit CG Select the appropriate kit required; the detailed installation instructions will be supplied with each kit. OTHER APPLICABLE ARTICLES: 83-11-12 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Air Separator > Component Information > Technical Service Bulletins > Customer Interest for Evaporative Emissions Air Separator: > 831112S > Sep > 84 > Fuel System - Stalls/No Start/Hesitation/ Stumble > Page 1495 ARTICLES SUPERSEDED: 82-14-21; 83-11-23 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. DLR. CODING: Basic Part No. 9237 Code: H6 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Air Separator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emissions Air Separator: > 831112S > Sep > 84 > Fuel System - Stalls/No Start/Hesitation/ Stumble Evaporative Emissions Air Separator: All Technical Service Bulletins Fuel System - Stalls/No Start/Hesitation/ Stumble Article No. 83-11-12-S STALLS/NO START/HESITATION/ STUMBLE - VAPOR LOCK (5.8L, 6.6L 7.5L) - VEHICLES OVER 8500 LBS. GVW LIGHT TRUCKS 1980/82 E250/350, F250/350 The service part numbers for kits "D" and "E" have been changed from E2UZ-9350-B to E0UZ-9350-D (Kit D) and E2UZ-9350-C to E0UZ-9350-C (Kit E) in TSB 83-11-12. The TSB Article is being reprinted showing the correct part numbers. NOTE: This TSB replaces TSB 82-14-21 dated July 16, 1982 in its entirety. DO NOT attempt to use TSB 82-14-21 to order service parts. Loss of road speed, hesitation, or engine stall on the subject vehicles operated at ambient temperatures over 85~F or at elevations over 4,500 feet, may be the result of fuel vaporization. A modification kit is available for vehicles experiencing this condition. It consists of an in-tank fuel pump, inertia shut-off switch, motorized fuel selector valve, vapor separator, and a vapor return system, along with related fuel lines and electrical wiring and devices. Before this modification is considered, other factors that could result in the same symptoms should be evaluated. Some of these include: ^ Plugged fuel filter at carburetor or tank. ^ Restricted fuel line. ^ Contaminated or low quality fuel. ^ Malfunctioning fuel pump or carburetor. If it is determined that the above factors have not caused the customer concern then the appropriate modification kit should be used to change the fuel system. Hardware Required: Components required to modify the vehicle differ with vehicle series, engine model and type of fuel tank. These have been packaged into 13 different kits. The chart that follows describes the specific kits that are required for the various vehicle configurations. Continued on next page TANK ENGINE (CID) KITS REQUIRED F-Series Single (Midship) 351M/400 A, F, H Single (Plastic Aft Axle) 351M/400 F, C, L Single (Metal Aft Axle) 351M/400 B, F, L Dual (Steel Aft Axle) 351M/400 A, B, F, I Dual (Plastic Aft Axle) 351M/400 A, C, F, I E-Series Single (Aft Axle) 351M/400 D, F, J Dual 351M/400 D, E, F, K E-Series Single (Aft Axle) 7.5L 460 D, G, J Dual 7.5L 460 D, E, G, K KIT SERVICE PART NO. DESCRIPTION CLASS A E2TZ-9350-D Fuel Pump/Sender Kit CG B E2TZ-9350-F Fuel Pump/Sender Kit CG C E2TZ-9350-C Fuel Pump/Sender Kit CG D E0UZ-9350-D Fuel Pump/Sender Kit CG E E0UZ-9350-C Fuel Pump/Sender Kit CG F E0TZ-9B328-A Vapor Separator Kit CG G E0TZ-9B328-B Vapor Separator Kit CG H E2TZ-9A350-H Fuel Line/Electrical Kit CG I E2TZ-9A350-F Fuel Line/Electrical Kit CG J E2UZ-9A350-F Fuel Line/Electrical Kit CG K E2UZ-9A350-D Fuel Line/Electrical Kit CG L E2TZ-9350-G Fuel Line/Electrical Kit CG Select the appropriate kit required; the detailed installation instructions will be supplied with each kit. OTHER APPLICABLE ARTICLES: 83-11-12 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Air Separator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emissions Air Separator: > 831112S > Sep > 84 > Fuel System - Stalls/No Start/Hesitation/ Stumble > Page 1501 ARTICLES SUPERSEDED: 82-14-21; 83-11-23 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. DLR. CODING: Basic Part No. 9237 Code: H6 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Charcoal Canister <--> [Evaporative Emission Control Canister] > Component Information > Locations Charcoal Canister: Locations Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Charcoal Canister <--> [Evaporative Emission Control Canister] > Component Information > Locations > Page 1505 Charcoal Canister: Description and Operation Fig. 53 Charcoal canister w/purge control valve WITH PURGE CONTROL VALVE The carbon canister stores fuel vapors from the fuel tank and carburetor until the engine is started. Fuel vapors enter the top of the purge side of the canister, Fig. 53, and travel in a ``U'' shape pattern to the fresh air vent side. Vapor flow to the engine is controlled by the purge control valve. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Charcoal Canister <--> [Evaporative Emission Control Canister] > Component Information > Locations > Page 1506 Fig. 54 Charcoal canister less purge control valve WITHOUT PURGE CONTROL VALVE The carbon canister, Fig. 54, stores fuel vapors from the fuel tank and carburetor bowl until the engine is started. At this time, fuel vapors are purged from the canister into the engine for combustion. Depending on application, either a 925ml or 1400ml canister is used. On vehicles equipped with a dual canister system, two canisters are linked together and the second canister is used for ``spill over'' fuel vapors. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Thermal Vacuum Valve - EVAP > Component Information > Description and Operation Thermal Vacuum Valve - EVAP: Description and Operation Fig. 22 Ported vacuum switches & vacuum control valves Fig. 23 Electrical vacuum switch These switches, Figs. 22 and 23, used on some vehicles, control vacuum to emission components during engine warm-up.The 2-port and 4-port types open when coolant temperature reaches a predetermined value. The 3-port type switches vacuum from the center to the top or bottom ports. Electrical switches can be opened or closed until the PVS is fully cycled. All PVS units are temperature-activated and have a specific opening and closing temperature. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Thermal Vacuum Valve - EVAP > Component Information > Description and Operation > Page 1510 Thermal Vacuum Valve - EVAP: Testing and Inspection Fig. 22 Ported vacuum switches & vacuum control valves Fig. 23 Electrical vacuum switch VACUUM SWITCH TEST 1. With engine cold, turn ignition key to ``ON,'' connect vacuum gauge to port A, Figs. 22 and 23, and a vacuum source to port B and then C. There should be no vacuum flow from A to B but there should be vacuum from A to C. 2. Start engine and run until it reaches normal operating temperature, then apply vacuum to port B and then port C. There should be vacuum from A to B but no vacuum from A to C. On 4-port valve, check A1 to B1 and A2 to B2 separately. 3. If vacuum flow is not as described, replace valve. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Vacuum Delay Valve, EVAP > Component Information > Description and Operation > Cold Start Spark Hold (CSSH) Vacuum Delay Valve: Description and Operation Cold Start Spark Hold (CSSH) This system, used on some vehicles, provides momentary spark advance hold during acceleration when the engine is cold, to provide improved cold engine acceleration. When engine coolant temperature is less than 128~ F, the CSSH PVS is closed and the distributor vacuum signal travels through the restrictor. When the engine is started cold, high vacuum acts on the vacuum advance unit to provide maximum advance. During acceleration, the high vacuum in the vacuum advance unit is slowly bled down through the restrictor, providing a modified vacuum advance during the initial stage of acceleration. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Vacuum Delay Valve, EVAP > Component Information > Description and Operation > Cold Start Spark Hold (CSSH) > Page 1515 Vacuum Delay Valve: Description and Operation Delay Vacuum Bypass (DVB) Delay vacuum bypass system - DVB Some vehicles are equipped with a delay vacuum bypass system as a part of the spark delay system (SDV). On all vehicles, Fig. 16, the DVB system is activated by a ported vacuum switch (PVS) and allows full spark port vacuum to the distributor vacuum advance when coolant is below PVS opening temperature. The system uses a spark delay valve (SDV), a check valve, and a 4 port PVS. When closed, the two bottom ports of the PVS are used. After opening, the top two ports are used, allowing vacuum to be routed through the SDV. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Vacuum Delay Valve, EVAP > Component Information > Description and Operation > Cold Start Spark Hold (CSSH) > Page 1516 Vacuum Delay Valve: Description and Operation Vacuum Delay Valves Fig. 32 Vacuum delay valve--VDV This valve, Fig. 32, used on some vehicles, further reduces emissions by delaying the spark advance during rapid acceleration and by cutting off advance immediately upon deceleration. This is a one-way valve and will not operate if installed backwards. On all systems which employ the dual diaphragm distributor, the line which has high vacuum at idle (normal operating temperature) is connected to the secondary (retard) side of the distributor vacuum advance unit. This is the connection closest to the distributor cap. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Vacuum Delay Valve, EVAP > Component Information > Testing and Inspection > Cold Start Spark Advance System (CSSA) Vacuum Delay Valve: Testing and Inspection Cold Start Spark Advance System (CSSA) NOTE: If engine is pinging, perform steps 1 thru 4. 1. Connect tachometer and start engine. CAUTION: Do not leave transmission in drive for more than 15 second while performing steps 2 and 4. 2. With parking brake applied, brake pedal depressed and transmission in drive, accelerate engine and observe RPM at which spark knock or pinging occurs. 3. Place transmission in neutral and accelerate engine to 1500 RPM to allow transmission to cool. Repeat this step three times. 4. Disconnect and plug vacuum advance line from distributor. Repeat step 2 to record RPM. 5. If spark knock or pinging reoccurred, stop engine and proceed to next step. If spark knock or pinging did not reoccur, the CSSA PVS and/or retard delay valve (if used) is faulty. Repair or replace as necessary. 6. Remove spark delay valve (SDV), or vacuum check valve, or spark delay valve and check as described further on. 7. Using a T-fitting, connect a vacuum gauge to distributor advance hose and disconnect and plug vacuum hose from bottom port of Cold Start PVS. 8. With engine idling at normal operating temperature, there should be no vacuum reading. If vacuum is obtained, the Cold Start PVS should be replaced. 9. Reconnect hose to bottom port of Cold Start PVS and disconnect and plug hose from top port of Cold Start PVS. 10. On vehicles with a cooling PVS, check vacuum at distributor with engine at normal idle. If reading is 2 inches Hg or less, the cooling PVS is operating properly. If vacuum reading is greater than specified, disconnect and plug the top vacuum line from the carburetor to the cooling PVS. If reading is still greater than specified, the cooling PVS should be replaced. 11. With engine idling in neutral, momentarily open the throttle half way. 12. Observe vacuum gauge for a quick rise and fall as throttle is opened and closed. If vacuum is obtained, the spark advance system is operating properly. If no vacuum is obtained, check vacuum line for leakage or obstruction and correct as necessary. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Vacuum Delay Valve, EVAP > Component Information > Testing and Inspection > Cold Start Spark Advance System (CSSA) > Page 1519 Vacuum Delay Valve: Testing and Inspection Delay Vacuum Bypass (DVB) 1. Remove air cleaner. 2. Remove spark delay valve. (Refer to Spark Delay Valve section for test procedure for this unit.) Replace spark delay valve with a connector. Remove vacuum line at distributor and install a vacuum line at distributor and install a T-fitting and a vacuum gauge. 3. With transmission in neutral and engine idling at normal operating temperature, open throttle to 1/2 open position. 4. Open and close throttle as noted in Step 3 while watching vacuum reading. A quick rise and fall should be noted. If vacuum is indicated, check the vacuum lines, evaporative canister purge valve. T-fitting, and carburetor vacuum port for blockage. Correct as necessary. 5. Turn off engine and replace the spark delay valve (tested before reinstalling as noted in Step 2). Remove vacuum gauge and T-fitting and replace vacuum hoses. 6. Remove vacuum check valve and test. (Refer to Spark Delay Valve section for test procedure for this unit). Replace if defective. Reinstall valve. 7. Install a T-fitting between the check valve and the PVS. Connect a vacuum gauge at this point. 8. With transmission in neutral and engine idling at normal operating temperature, open throttle to 1/2 position. Note vacuum reading at steady 1/2 throttle. If reading is 2 inches Hg or less, PVS unit is good. If more than 2 inches Hg is indicated, PVS is defective and must be replaced. 9. Remove vacuum gauge and return all vacuum lines to original location. Reinstall air cleaner assembly. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Vacuum Delay Valve, EVAP > Component Information > Testing and Inspection > Cold Start Spark Advance System (CSSA) > Page 1520 Vacuum Delay Valve: Testing and Inspection Vacuum Delay Valve Using a suitable hand held vacuum pump, apply vacuum to both sides of valve. On valve with one side black or white and the other side a different color , vacuum should build up in one side but not the other. On valve with both side the same color, vacuum should build up on both sides before visibly decreasing. If valve does not function in this manner, it should be replaced. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Backpressure Transducer > Component Information > Description and Operation EGR Backpressure Transducer: Description and Operation Fig.49 - Integral EGR Valve Exhaust Back-pressure Transducer This valve, Fig. 49, performs the same function as the non-integral back pressure transducer used on some systems. The valve assembly has an internal exhaust gas chamber with a transducer diaphragm which senses exhaust back pressure through a hollow stem. When back pressure is low, vacuum is bled through the transducer valve and the EGR valve stem remains closed. When back pressure increases, the transducer diaphragm moves up and closes the transducer valve vacuum bleed hole. With the vacuum bleed closed, the EGR valve opens, allowing exhaust gas to flow into the intake manifold. Because the EGR outlet is always exposed to manifold vacuum and EGR gas inlet flow is restricted by an orifice, back pressure at the transducer drops when the EGR valve opens. When the back pressure drops, the vacuum bleed hole opens, closing the EGR valve and allowing pressure to build up again. The cycle is continually repeated, modulating the flow of exhaust gas into the intake manifold. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Technical Service Bulletins > EGR Solenoids - Contamination EGR Control Solenoid: Technical Service Bulletins EGR Solenoids - Contamination Article No. 85-13-5 EGR SOLENOIDS - CONTAMINATION FORD 1980-1985 ALL WITH ELECTRONIC EGR CONTROL AND VENT SOLENOIDS LINCOLN-MERCURY 1980-1985 ALL WITH ELECTRONIC EGR CONTROL AND VENT SOLENOIDS The use of starter fluids (ether and xylene), choke and/or fuel injector cleaners, can contaminate the EGR control and vent solenoids EGRC/EGRY. These solvents may affect the upper elastomer tip of the solenoid armature, causing an inoperative condition. Care must also be used to avoid getting these starter fluids into the vacuum harness, and contaminating these emission components in this way. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Vacuum Regulator Solenoid <--> [EGR Electronic Vacuum Regulator Solenoid] > Component Information > Technical Service Bulletins > EGR Solenoids - Contamination EGR Vacuum Regulator Solenoid: Technical Service Bulletins EGR Solenoids - Contamination Article No. 85-13-5 EGR SOLENOIDS - CONTAMINATION FORD 1980-1985 ALL WITH ELECTRONIC EGR CONTROL AND VENT SOLENOIDS LINCOLN-MERCURY 1980-1985 ALL WITH ELECTRONIC EGR CONTROL AND VENT SOLENOIDS The use of starter fluids (ether and xylene), choke and/or fuel injector cleaners, can contaminate the EGR control and vent solenoids EGRC/EGRY. These solvents may affect the upper elastomer tip of the solenoid armature, causing an inoperative condition. Care must also be used to avoid getting these starter fluids into the vacuum harness, and contaminating these emission components in this way. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Vacuum Regulator Solenoid <--> [EGR Electronic Vacuum Regulator Solenoid] > Component Information > Technical Service Bulletins > Page 1533 EGR Vacuum Regulator Solenoid: Locations LH Side Of V8-302/5. Attached to LH Valve Cover Applicable to: 0L Engine Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation EGR Valve: Description and Operation In this system the exhaust gases are reintroduced to the combustion cycle, therefore diluting the air fuel mixture entering the combustion chambers. Dilution of the incoming mixture lowers peak flame temperatures during combustion and thus limits the formation of nitrogen oxides (NOx). Fig. 46 Spacer entry EGR connection Some engines use the ``Spacer Entry'' EGR System which has the EGR valve mounted on the carburetor spacer, Fig. 46. The exhaust gases are taken from a drilled passage in the exhaust crossover of the intake manifold. The exhaust gas is then routed through a metered EGR valve to a passage in the carburetor spacer and fed into the primary bore. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > Page 1537 Fig. 47 Intake manifold mounted EGR connection On some engines, the EGR system routes exhaust gas directly from the exhaust manifold, Fig. 47. Two variables control the operation of the EGR system, 1) engine coolant temperature and 2) engine or carburetor vacuum. When engine coolant temperature is below the specified level, the EGR system is locked out by a temperature controlled vacuum switch. This vacuum switch is installed in series with the EGR valve. This valve receives vacuum from a port in the carburetor body. When the valve is closed due to lower coolant temperature, no vacuum is applied to the EGR valve and no exhaust gas is fed to the air-fuel mixture. When the engine coolant temperature reaches the specified level, the valve opens allowing vacuum to be applied to the EGR valve. Exhaust gas is then fed to the air-fuel mixture. The second factor controlling EGR operation is carburetor vacuum. The location of the EGR port in the carburetor determines at what point vacuum is sent to the EGR valve. Vacuum should be fed to the EGR vacuum control valve when the primary throttle plate reaches a position corresponding to a road speed of approximately 20 mph under light acceleration. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > Page 1538 Fig. 48 Venturi vacuum amplifier A Venturi Vacuum Amplifier, Fig. 48, uses a weak venturi vacuum signal to produce a strong intake manifold vacuum to operate the EGR valve, thereby achieving an accurate, repeatable and almost exact proportion between venturi airflow and EGR flow. This assists in controlling oxides of nitrogen with minimal sacrifice in driveability. There are four basic types of EGR valves: the ported type, the integral back pressure type, the electronic-sonic type and the valve and transducer assembly type The electronic-sonic type valve is used with the EEC system. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > Page 1539 Fig. 6 EGR valve position sensor This sensor, Fig. 6, is used to monitor the EGR valve pintle position. The computer applies a reference voltage to the EVP sensor, and the resulting signal from the EVP sensor is proportional to the amount of exhaust gases flowing through the EGR valve pintle into the intake manifold. Depending on the input from this and other sensors, the computer can increase or decrease EGR flow by activating or deactivating a pair of solenoid vacuum valves. Fig. 49 Ported type EGR valves Ported type valves, Fig. 49, may be of the poppet or tapered stem design and can have base or side entry. The two passages connecting the exhaust system to intake manifold are blocked by a valve which is opened by vacuum and closed by spring pressure. Fig. 50 Integral back pressure transducer EGR valve The integral back pressure transducer valve, Fig. 50, cannot be opened by vacuum until the bleed hole is closed by exhaust back pressure. When open, the valve oscillates at a level dependent on the exhaust back pressure flowing through the orifice. Valve opening increases as signal vacuum and exhaust back pressure increases. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Description and Operation > Page 1540 Fig. 51 EGR valve w/remote back pressure transducer Some vehicles use an EGR valve with a remote back pressure transducer, Fig. 51. This assembly operates the same as the EGR valve with integral back pressure transducer valve and is serviced only as an assembly. Some vehicles use a variable transducer type EGR valve and consists of three components; a vacuum regulator, EGR valve and a flow control orifice. The regulator modulates the vacuum signal to the EGR valve using two back pressure inputs. One input is the standard vehicle back pressure and the other is the back pressure down stream of the flow control orifice. The control chamber pickup is in the EGR tube and the flow control orifice is integral with the upstream EGR tube connector. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Locations EGR Valve Position Sensor: Locations LH Side Of V8-302/5. At Center Engine To Rear Of Carburetor Applicable to: 0L Engine Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Locations > Page 1544 EGR Valve Position Sensor: Description and Operation Fig. 6 EGR valve position sensor This sensor, Fig. 6, is used to monitor the EGR valve pintle position. The computer applies a reference voltage to the EVP sensor, and the resulting signal from the EVP sensor is proportional to the amount of exhaust gases flowing through the EGR valve pintle into the intake manifold. Depending on the input from this and other sensors, the computer can increase or decrease EGR flow by activating or deactivating a pair of solenoid vacuum valves. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Exhaust Pressure Regulator Vacuum Valve, EGR > Component Information > Testing and Inspection Exhaust Pressure Regulator Vacuum Valve: Testing and Inspection 1. Run engine at normal operating temperature and set throttle on high cam on 4-140 engine or on kickdown step on other engines. 2. Connect vacuum gauge to EGR side of load control valve and note reading. 3. Apply a vacuum of at least 6 inches Hg to venturi port of valve. If gauge does not drop to zero, replace valve. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Thermal Vacuum Valve, EGR > Component Information > Description and Operation Thermal Vacuum Valve: Description and Operation Fig. 22 Ported vacuum switches & vacuum control valves Fig. 23 Electrical vacuum switch These switches, Figs. 22 and 23, used on some vehicles, control vacuum to emission components during engine warm-up.The 2-port and 4-port types open when coolant temperature reaches a predetermined value. The 3-port type switches vacuum from the center to the top or bottom ports. Electrical switches can be opened or closed until the PVS is fully cycled. All PVS units are temperature-activated and have a specific opening and closing temperature. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Thermal Vacuum Valve, EGR > Component Information > Description and Operation > Page 1551 Thermal Vacuum Valve: Testing and Inspection Fig.50 - EGR-PVS Opening Temperature Chart Switches With Two Connectors 1. Disconnect both vacuum hoses at switch. Connect a vacuum gauge to either connector on switch. Connect an external vacuum source at least 10 inches Hg or manifold vacuum to other connector on switch. 2. Start engine and allow coolant to exceed the calibration temperature of the switch as indicated in chart in Fig. 50, according to color code. 3. If there is no vacuum reading after coolant temperature exceeds the calibration point of the switch, the PVS switch is defective and should be replaced. If there is a vacuum reading, the switch is functioning properly. Switches With Three Connectors 1. Disconnect EGR vacuum hose at carburetor and connect manifold vacuum or external vacuum source to hose. 2. Disconnect EGR vacuum hose at EGR valve and connect vacuum gauge to hose. 3. Start engine and allow coolant temperature to exceed calibration point of switch as indicated in chart in Fig. 50, according to color code. 4. There should be a vacuum reading at gauge after coolant temperature exceeds calibration point of switch. If not, the switch is defective and should be replaced. Switches With Four Connectors 1. Disconnect vacuum hoses at PVS valve, then connect a vacuum gauge to either port marked D and M, and connect an external vacuum source to other port. 2. Start engine and allow coolant temperature to exceed calibration point of PVS valve as indicated in Fig. 50, according to color code. 3. If there is a vacuum reading after coolant temperature has exceeded calibration temperature of PVS valve, valve is defective and should be replaced. If there is no vacuum reading, that portion of valve is functioning properly. 4. Connect vacuum gauge to either bottom ports marked E and S and other port to vacuum supply. 5. There should be a vacuum reading at gauge with coolant temperature above the calibration point of the PVS valve. If not, the PVS valve is defective and should be replaced. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Description and Operation Positive Crankcase Ventilation Valve: Description and Operation Fig. 62 Typical PCV system Fig. 63 Typical PCV valve All engines produce small amounts of blowby gases which seep past the piston rings and into the crankcase. These blowby gases are the result of the high pressures developed within the combustion chamber during the combustion process, and contain undesirable pollutants. To prevent blow-by gases from entering atmosphere while allowing proper crankcase ventilation, all engines use a PCV system, Fig. 62. The PCV system prevents blowby gases from escaping by routing them through a vacuum controlled ventilating valve and a hose into the intake manifold. The blowby gases mix with the air/fuel mixture and are burned in the combustion chambers. When the engine is running, fresh air is drawn into the crankcase through a tube or hose connected to the air cleaner housing. The PCV valve, Fig. 63, consists of a needle valve, spring and housing. When the engine is off, the spring holds the needle valve closed to stop vapors from entering the intake manifold. When the engine is running, manifold vacuum unseats the valve allowing crankcase vapors to enter the intake manifold. In case of a backfire in the intake manifold, the valve closes, stopping the backflow and preventing ignition of fumes in the crankcase. During certain engine conditions, more blowby gases are created than the ventilator valve can handle. The excess is returned through the air intake tube to the air cleaner and carburetor where it is burned in the engine. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Description and Operation > Page 1556 Positive Crankcase Ventilation Valve: Testing and Inspection 1. Pull end of PCV valve out of valve cover. If valve rattles when shaken, proceed to step 2. If not, replace valve. 2. Disconnect vacuum hose from air cleaner and feel for vacuum at hose with engine at idle. If vacuum is felt, system is satisfactory. If no vacuum is felt, check for obstructions in PCV system or a leaking evaporative valve. 3. Disconnect evaporative hose, then cap the tee fitting and retest. If vacuum is now felt, PCV system is satisfactory. Check evaporative system. If no vacuum is felt, check for vacuum back through the system and inspect rocker cover gasket for leaks. Repair or replace components as necessary. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Locations EGR Valve Position Sensor: Locations LH Side Of V8-302/5. At Center Engine To Rear Of Carburetor Applicable to: 0L Engine Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Locations > Page 1561 EGR Valve Position Sensor: Description and Operation Fig. 6 EGR valve position sensor This sensor, Fig. 6, is used to monitor the EGR valve pintle position. The computer applies a reference voltage to the EVP sensor, and the resulting signal from the EVP sensor is proportional to the amount of exhaust gases flowing through the EGR valve pintle into the intake manifold. Depending on the input from this and other sensors, the computer can increase or decrease EGR flow by activating or deactivating a pair of solenoid vacuum valves. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Inlet Air Temperature Control <--> [Thermostatic Air Cleaner] > Thermostatic Air Cleaner Vacuum Switch > Component Information > Description and Operation > Auxiliary Air Inlet Valve Thermostatic Air Cleaner Vacuum Switch: Description and Operation Auxiliary Air Inlet Valve Fig.5 - Auxiliary Air Inlet Valve The auxiliary air inlet valve is mounted on the outside of the air cleaner housing and serves to allow outside air to bypass the heated air inlet system when the engine is under load. When manifold vacuum is low, a spring in the vacuum motor allows the valve to open, providing an additional flow of air into the air cleaner housing, Fig. 5. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Inlet Air Temperature Control <--> [Thermostatic Air Cleaner] > Thermostatic Air Cleaner Vacuum Switch > Component Information > Description and Operation > Auxiliary Air Inlet Valve > Page 1567 Thermostatic Air Cleaner Vacuum Switch: Description and Operation Cold Weather Modulator Fig.4 - Cold Weather Modulator This modulator, Fig. 4, located in the air cleaner housing of some 1975-82 Ford vehicles, prevents the air cleaner door from opening to non-heated outside air at ambient temperatures below 55° F. At ambient temperatures above 55° F., the modulator is inoperative. During acceleration at ambient temperatures below 55° F., the modulator located in-line between the bi-metal sensor and vacuum duct motor, will close off vacuum to the motor and hold the duct open. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Inlet Air Temperature Control <--> [Thermostatic Air Cleaner] > Thermostatic Air Cleaner Vacuum Switch > Component Information > Description and Operation > Page 1568 Thermostatic Air Cleaner Vacuum Switch: Testing and Inspection Procedure 1. Cool modulator to below 40° F (except black modulator) or 20° F (black modulator). Allow enough time for modulator temperature to stabilize and modulator valve to close. 2. On 1975-76 systems, use an external vacuum source and apply at least 16 inches Hg vacuum to vacuum motor side and trap vacuum by pinching hose. Modulator must hold at least 14 inches Hg vacuum for 60 seconds. If not, replace modulator. 3. On 1977-80 systems, use a 24 inch length of 1/4 inch hose between cold weather modulator and vacuum gauge. Using an external vacuum source, apply at least 16 inches Hg vacuum to vacuum motor side of modulator and trap vacuum by pinching hose. The modulator must hold at least 5 inches Hg vacuum for 30 seconds. If not, replace modulator. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Vacuum Restrictor > Component Information > Description and Operation Vacuum Restrictor: Description and Operation Fig.30 - Vacuum Restrictor The orifice type flow restrictor, Fig. 30, is used on some systems to control the flow rate and or timing characteristics to the following systems: a. EGR valve timing (opening and closing). b. Part throttle spark advance. c. Purge system. d. Thermactor system The flow rate through the restrictor is the same in both directions. If blocked, it should be replaced. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications SPECIFICATIONS Pressure .............................................................................................................................................. .............................................................. 6.0-8.0 PSI Volume .............................................................. ................................................................................................................................. 1 pint in 20 seconds NOTE: Measurements taken with engine idling. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications > Page 1576 Fuel Pressure: Testing and Inspection PRESSURE TEST 1. Connect a suitable pressure gauge (0-15 PSI) to the carburetor end of the fuel line. WARNING: Use care to prevent combustion of spilled fuel. 2. Start the engine (it should be able to run for over 30 seconds on the fuel in the carburetor bowl) and read the pressure after 10 seconds. If pump pressure is too low or too high install a new fuel pump. Fuel Pump Pressure ............................................................................................................................ ................................................. 6.0-8.0 PSI 3. Reconnect fuel line at filter and install air cleaner. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications IDLE SPEED SPECIFICATIONS Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Adjustments > Curb Idle Speed Idle Speed: Adjustments Curb Idle Speed Identification CARBURETOR IDENTIFICATION 2150-2V, 2150A-2V Carburetor Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Adjustments > Curb Idle Speed > Page 1582 Variable Venturi, 7200-VV Carburetor Type 2150-2V CURB IDLE SPEED ADJUSTMENT - Place the transmission in Neutral (manual) or Park (automatic). - Bring engine to normal operating temperature (upper radiator hose hot). - Place the transmission in the specified gear. See: Specifications Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Adjustments > Curb Idle Speed > Page 1583 - Check curb idle rpm. Adjust to specification. See: Specifications - Place the transmission in Neutral (manual) or Park (automatic). Rev the engine momentarily. Place the transmission in specified position, and recheck curb idle rpm. Readjust if required. Type 7200-VV Carburetor CURB IDLE SPEED ADJUSTMENT - Place the transmission in Neutral (manual) or Park (automatic). - Bring the engine to normal operating temperature. - Disconnect purge hose on canister side of evaporator purge solenoid. Check to ensure that purge vacuum is present (solenoid has opened, will require a 3-5 minute wait after starting engine, followed by a short time at part throttle. Reconnect purge hose. - Disconnect and plug the vacuum hose to the Vacuum Operated Throttle Modulator (VOTM) kicker. - Place the transmission in specified position. See: Specifications With Automatic Transmission Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Adjustments > Curb Idle Speed > Page 1584 With Manual Transmission - Check/adjust curb idle rpm. See: Specifications - Place the transmission in Neutral or Park. Rev the engine momentarily. Place the transmission in specified position and recheck curb idle rpm. Readjust if required. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Adjustments > Curb Idle Speed > Page 1585 Idle Speed: Adjustments Fast Idle Speed Identification CARBURETOR IDENTIFICATION 2150-2V, 2150A-2V Carburetor Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Adjustments > Curb Idle Speed > Page 1586 Variable Venturi, 7200-VV Carburetor Type 2150-2V Carburetor FAST IDLE SPEED ADJUSTMENT - Place the transmission in Park (automatic) or Neutral (manual). - Bring the engine to normal operating temperature. - Disconnect the vacuum hose at the EGR valve and plug. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Adjustments > Curb Idle Speed > Page 1587 - Place the fast idle adjustment mechanism on top step of fast idle cam. Check/adjust fast idle rpm to specification. See: Specifications - Recheck for repeatability. - Remove the plug from the EGR vacuum hose and reconnect. Type 7200-VV Carburetor FAST IDLE SPEED ADJUSTMENT - Place the transmission in Neutral (manual) or Park (automatic). - Bring the engine to normal operating temperature. - Disconnect purge hose on canister side of evaporator purge solenoid. Check to ensure that purge vacuum is present (solenoid has opened, will require a 3-5 minute wait after starting engine, followed by a short time at part throttle. Reconnect purge hose. Disconnect the vacuum hose at the EGR valve and plug. - Place the fast idle adjustment mechanism on the second step of the fast idle cam. - Check/adjust fast idle rpm to specification. Recheck for repeatability. See: Specifications - Remove the plug from the EGR vacuum hose and reconnect. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Component Information > Technical Service Bulletins > Air Cleaner - Sealing Procedure Air Cleaner Housing: Technical Service Bulletins Air Cleaner - Sealing Procedure Article No. 83-25-21-S AIR CLEANER SEALING - 4.9L (1982-83 F-SERIES AND BRONCO ONLY) AND ALL UNITS WITH 5.0L, 5.8L OR 7.5L ENGINES. UNITS OPERATED IN DUSTY AND/OR OFF-ROAD CONDITIONS ARTICLE ALSO INCLUDES SEALING OF 7200VV CARBURETOR ON UNITS SO EQUIPPED LIGHT TRUCKS 1980-83 E, F AND BRONCO This is a re-write of TSB 83-25-21 (December 12, 1983). The air cleaner part numbers listed in the TSB are of insufficient detail and are therefore being deleted from the TSB. Due to the variety of different air cleaners used, part numbers have not been included in this TSB. See your normal parts listing for these part numbers. The subject vehicles operated in dusty/off-road conditions may experience an air cleaner sealing concern which could lead to engine oil consumption or, on 7200 VV carburetor equipped vehicles, a poor running condition. The following procedure should minimize these concerns. 1. Remove the air cleaner assembly from the engine and remove any loose debris from inside the tray. Replace the air cleaner assembly (9600) on all 1983 4.9L, 5.0L, 5.8L and, 7.5L equipped light trucks except the 1983 Econoline with the 4.9L engine. Due to the variety of different air cleaners used, part numbers have not been included in this TSB. See your normal parts listings for these part numbers. 2. Wipe the sealing surfaces clean on the tray and cover and inspect for any dents or damage that would prevent a good seal. Replace any damaged components. 3. Inspect the air cleaner to carburetor gasket for proper installation. If the gasket appears crimped or damaged, replace it with a new sticky-back gasket. Prior to replacing the gasket, clean the carburetor flange. Install the new gasket sticky side down and press all the gasket down to assure a tight bond. Gasket parts numbers: 4.9L - C8DZ-9654-A, 5.0L/5.8L/7.5L - D8ZZ-9654-A. FIGURE 24 4. For F-Series and Bronco only, relocate the zip tube inlet. a) Detach the zip tube inlet from the radiator support. b) Move the inlet to the top rear of the wheel wellhousing per Figure 24. c) Secure the zip tube to the top of the housing with a nylon tie-down strap. NOTE: At high temperatures, an octane ping may occur. If it persists, the zip tube must be reinstalled to the radiator support. 5. Replace the PCV filter. For 4.9L, 5.0L-2V, 5.8L-2V and 7.5L-4V engines replace the PCV filter in the air cleaner with an in-line filter. a. Remove and discard the crankcase breather cap to PCV filter hose (closure hose), PCV filter in the air cleaner, the adapter at the air cleaner and the adapter retaining clip. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Component Information > Technical Service Bulletins > Air Cleaner - Sealing Procedure > Page 1592 b. Drill a 5/16" hole in the side wall of the air cleaner approximately 12" to the rear of the existing crankcase closure hole for 5.0L and 5.8L and approximately 6" to the rear on 7.5L. (The 4.9L does not need a new hole). c. Install a 1/2" hose (E2AZ-6853-A) to the existing adaptor in the valve cover oil fill cap (2 pcs. 2-5/8" long for 4.9L, 18" long for 5.0L/5.8L, 12" long for 7.5L). d. At a convenient location, cut the hose and install an in-line filter E2AZ-6A768-A for 5.0L, 5.8L and 7.5L. On the 4.9L, install the filter between the 2-5/8" long pieces installed in (c.). NOTE: Install the filter with the wire mesh toward the oil fill cap. The mesh can be seen by looking into the end of the filter assembly. e. Install an adapter E43Z-9E606-A in the air cleaner and attach using a retaining clip 383741-S. Center the adapter elbow in the new hole for 5.0L, 5.8L and 7.5L. Use the existing PCV filter (closure) pack hole for 4.9L. f. Cut the PCV filter (closure) hose to proper length and attach to the adapter. g. Plug the old hole in the tray with plug 377678-S for 5.0L, 5.8L and 7.5L only. FIGURE 25 6. For 5.0L and 5.8L engines with a 7200 VV carburetor, clean and seal the carburetor to prevent dirt migration through the choke rod and accelerator pump rod holes (Refer to Figure 25). a. Remove the carburetor from the vehicle. b. Without disassembling the carburetor, thoroughly clean with Ford Automatic Choke Cleaner or equivalent, all of the choke linkage and accelerator pump linkage on the top and sides of the carburetor. Pay particular attention to the top and bottom of the upper body casting around the choke and accelerator pump rods. Allow cleaner to evaporate or blow dry with shop air. c. Remove stepper motor, gasket, pintle and spring. Clean pintle and pintle cavity in main body casting thoroughly with Ford Automatic Choke Cleaner or equivalent. Do not re-install stepper motor at this time. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Component Information > Technical Service Bulletins > Air Cleaner - Sealing Procedure > Page 1593 FIGURE 24 d. Hold throttle lever in the wide-open throttle position to raise the accelerator pump rod. With a toothpick, or other sharp tool, apply any commercially available silicone RTV (such as Dow Corning "Silastic") to the top side of the upper body casting around the accelerator pump rod (Figure 24). Fill the hole completely around the rods from the top side only and release the throttle lever. e. With a rubber band, tie the throttle lever in closed-throttle position. Push fast idle cam to "off" position so that choke rod is fully raised. Fast idle cam should remain in "off" position. f. With a toothpick, apply silicone RTV to bottom side of upper body casting around the choke shaft rod. Fill the hole completely around the rod from the bottom side only. g. Install the spring, pintle, gasket, and stepper motor. h. Allow carburetor to stand at room temperature for 24 hours without disturbing silicone RTV. i. After 24-hour cure, remove rubber band from throttle lever, and open throttle to break (free) accelerator pump rod from silicone RTV. Bulk of RTV sealant should remain attached to upper body. j. Manually exercise choke linkage to break (free) choke rod from silicone RTV. Bulk of RTV sealant should remain attached to upper body. k. Re-install carburetor on vehicle. 7. Re-install and secure the air cleaner assembly as follows: a. Set the air cleaner tray assembly on the carburetor and check that nothing is preventing the tray seating securely and completely sealing the flange. b. Connect and secure the vacuum hoses. c. Install and seat a new heavy duty air cleaner element in the tray. Use E2TZ-9601-B (FA-732) for 4.9L and E0TZ-9601-A (FA-688) for 5.0L/5.8L. Use non-heavy duty element for 7.5L. NOTE: Use of incorrect element will allow dirt to be ingested and will damage the engine. d. Install the air cleaner cover and place the washer grommet rubber side down. Torque the wing nut hand tight (20 in.lbs.). Try to rotate the air cleaner assembly slightly. If it resists rotation, sealing to the carburetor is assured. e. Connect the crankcase filter hose securely. f. Install the heat riser tube. Connect the fresh air zip tube. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Component Information > Technical Service Bulletins > Air Cleaner - Sealing Procedure > Page 1594 Obtain an Authorized Modifications decal and list the date, dealer number and summary of alterations performed. Select a prominent place adjacent to the Vehicle Emission Control Information decal suitable for installing the Authorized Modifications decal. Clean the area, install the decal and cover it with a clear plastic decal shield. PART NUMBER PART NAME CLASS E2AZ-6A768-A PCV Filter C E2AZ-6853-A 1/2" PCV Hose C E43Z-9E606-A Adapter C E2TZ-9601-B Air Filter Element AM E0TZ-9601-A Air Filter Element AM C6TZ-9697-A Washer AM D8ZZ-9654-A Gasket A 377678-S Plug BR E3AZ-19562-A RTV Sealer A 390013-S36B Wing Nut S C8DZ-9654-A Gasket AM OTHER APPLICABLE ARTICLES: 83-25-21 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP9600C84 TIME: 6 cyl. - 0.5 Hr. 8 cyl. - 1.1 Hrs. DLR. CODING: Basic Part No. 9600 Code: 49 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Accelerator Pump > Component Information > Technical Service Bulletins > Service Labor Time Standards Revision Accelerator Pump: Technical Service Bulletins Service Labor Time Standards Revision REVISED SERVICE LABOR TIME STANDARDS Article No. 87-8-20 LIGHT TRUCK: 1981-84 F-100/350, ECONOLINE, BRONCO ISSUE: Labor operations 9424A, (Intake manifold - remove and install or replace) and 9631A (Accelerator pump diaphragm or piston rod (carburetor) - replace) have been revised. ACTION: The new labor allowances are as follows: Operation 9424A Intake Manifold - Remove and Install or Replace New allowance for 1981-84 Econoline (5.0L and 5.8L) . . . . . . . . . . . . . . . . . . . . 3.2 Hrs. Operation 9631A Accelerator Pump, Diaphragm or Piston Rod (Carburetor) - Replace New allowance for all 8-cyl. engines (1984 only) . . . . . . . . . . . . . . . . . . . . . . 1.3 Hrs. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Bowl Vent Solenoid > Component Information > Description and Operation Bowl Vent Solenoid: Description and Operation Fig. 9 Carburetor fuel bowl solenoid vent valve This valve, Fig. 9, used on some vehicles, is a normally open valve located in the fuel bowl vent line to the carbon canister. When the engine is running, the valve closes off the fuel bowl vent line. When the engine is shut off, the vent line returns to the normally open condition. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Bowl Vent Solenoid > Component Information > Description and Operation > Page 1603 Bowl Vent Solenoid: Testing and Inspection Apply 12 volts to valve. The valve should close, allowing no air to pass. NOTE: If a lean fuel mixture is suspected of causing a problem, inspect either the solenoid vent valve or the fuel bowl vent valve for proper closing during engine operation. If the valve opens, allowing purged vacuum to affect fuel bowl balanced air pressure, the carburetor will give a leaner air/fuel mixture. On EEC equipped engines with a 7200 VV feedback carburetor (back-suction type only), the opposite (rich mixture) will result from an open or leaking valve. CAUTION: The utmost care should be exercised when using a torch in the area of the fuel evaporation system as an open flame near these hoses may cause a fire and ultimate explosion. NOTE: Vapor line hoses used in these systems are made from a special rubber material. Bulk service hoses are available for service and will be marked "EVAP". Ordinary fuel hoses should not be used. They are subject to deterioration and may clog system. CAUTION: Installation of a fill cap from a non-emission fuel tank will render the system inoperative, since the non-emission fill cap is vented and the system must be sealed to function properly. Also if a non-vented fill cap is installed on a conventional tank, the result will be a serious deformation or a total collapse of the fuel tank. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Carburetor Float > Component Information > Specifications Carburetor Float: Specifications 1981-82 7200 VV ADJUSTMENT SPECIFICATIONS 1982 2150 2V ADJUSTMENT SPECIFICATIONS Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Carburetor Float > Component Information > Adjustments > Float Drop Carburetor Float: Adjustments Float Drop Fig. 5 Float drop adjustment 1. Position upper body assembly in upright position, then place gauge, Fig. 5, against cast surface of upper body and measure vertical distance between cast surface of upper body and bottom of float. Do not place gauge on gasket. 2. To adjust, bend stop tab on float lever away from hinge pin to increase setting and toward hinge pin to decrease setting. 3. Install upper body assembly. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Carburetor Float > Component Information > Adjustments > Float Drop > Page 1609 Carburetor Float: Adjustments Fuel Level Fig. 4 Fuel level adjustment 1. Remove upper body assembly, then remove upper body gasket. Install new gasket prior to performing adjustment. 2. Invert upper body, then position fuel level gauge, Fig. 4, onto cast surface of upper body and measure vertical distance between cast surface of upper body and bottom of float. Do not place gauge on gasket. 3. To adjust, bend float operating lever away from fuel inlet needle to decrease setting and toward needle to increase setting. Check and adjust float drop. Float pontoon must be parallel with gasket. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Carburetor Solenoid > Component Information > Locations Carburetor Solenoid: Locations RH Side Of V8-302/5. RH Side Of Engine Applicable to: 0L & V8-351/5.8L California Engines w/EEC Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Choke Housing > Component Information > Technical Service Bulletins > Electric Choke System - Testing Tool Choke Housing: Technical Service Bulletins Electric Choke System - Testing Tool Article No: 82-10-13 May 24, 1982 Subject: Rotunda Choke Cap Tester No. 90-0001 FORD All Vehicles With Single - And Two-stage Electric Chokes LINCOLN-MERCURY All Vehicles With Single - And Two-stage Electric Chokes The tool was recently released to improve performance and reduce diagnosis time when servicing choke systems. Testing time has been reduced to a few minutes with the all electric two-stage choke system. The temperature range of the tester is from -1 °F to 165 °F. For optimum tool performance, shop air with a line pressure of 90 PSI with 6-8 C.F.M. volume is required. An adaptor is provided to service older model single-stage and hot-air-only systems. The unit is also recommended for testing other heat sensitive/actuated components and auto/temp control systems. Refer to the Engine/Emission/Diagnosis Manual and the Manufacturers Instruction Manual (provided) for procedures and instructions. Warranty Status: Information Only Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Choke Plate > Component Information > Specifications 1982 2150 2V ADJUSTMENT SPECIFICATIONS Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Choke Plate > Component Information > Specifications > Page 1620 Choke Plate: Adjustments Fig. 6 Dechoke clearance adjustment 1. Hold throttle in the wide open position and measure clearance between lower edge of choke plate and air horn wall using the specified size drill. 2. To adjust clearance, bend metal tang on fast idle speed lever attached to throttle shaft, Fig. 6. 3. Rotate throttle lever to ensure minimum throttle effort during dechoke tang engagement. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Choke Pull-off > Component Information > Adjustments Choke Pull-off: Adjustments Fig. 8 Fast idle cam assemblies Fig. 9 Choke plate clearance 1. Set throttle on fast idle cam top step, Fig. 8, then loosen choke thermostatic housing retaining screws and set housing 90° in rich direction. 2. Activate pulldown motor by manually forcing pulldown control diaphragm link in direction of applied vacuum or by applying vacuum to external vacuum tube. 3. Check clearance between choke plate and center of carburetor air horn wall nearest fuel bowl, Fig. 9. Refer to the Specifications Chart. If clearance is not as specified, reset by adjusting diaphragm stop on end of choke pulldown diaphragm. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Technical Service Bulletins > Alternator - Replacement Precautions Electric Assist Choke: Technical Service Bulletins Alternator - Replacement Precautions Article No. 85-12-24 RICH MIXTURE - CHOKE DOES NOT OPEN - ELECTRIC CHOKE CONNECTION TO NON-OEM ALTERNATOR LIGHT TRUCK ALL SERIES Replacement of the OEM alternator to accomodate higher current requirements of vehicle-mounted electrical equipment may adversely affect the operation of the electric choke on those vehicles so equipped. For this reason, it is important to examine the electrical system on a subject vehicle to determine if an electric choke is connected to the OEM alternator stator terminal. If there is such a connection, a similar connection must be provided on the replacement alternator. Contact the manufacturer of the replacement alternator to determine the correct method of connecting to the alternator stator. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Technical Service Bulletins > Page 1628 Electric Assist Choke: Description and Operation Fir. 38 - Typical Electric Assist Choke Installation Fig.39 - Electric Assist Choke Wiring Schematic Purpose Most 1973-82 models are equipped with an electric assist choke to reduce hydrocarbon (HC) and carbon monoxide (CO) emissions during starting and warm-up--choke on--period. The electric assist choke is designed to give a more rapid choke opening at temperatures of about 60° to 65° F, or higher. It also provides a slower choke opening at temperatures below this point. Operation Current is constantly supplied to the ambient temperature switch. The system is grounded through a ground strap connected to the carburetor body. At temperatures below approximately 60 degrees, the switch opens and no current is supplied to the ceramic heater located within the thermostatic spring. Normal thermostatic spring choking action then occurs. At temperatures above approximately 60-65 degrees, the temperature sensing switch closes and current is supplied to the ceramic heater. As the heater warms, it causes the thermostatic spring to pull the choke plates open within 1-1/2 minutes. The electric assist choke system does not change any carburetor service procedures and cannot be adjusted. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Technical Service Bulletins > Page 1629 If system is found out of calibration the heater control switch and/or choke unit must be replaced. Construction The electric choke system, Figs. 38 and 39, consists of a choke cap, thermostatic spring, a bimetal temperature sensing disc (switch), and a ceramic positive temperature coefficient (PTC) heater. The choke is powered from terminal or tap of the alternator. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Technical Service Bulletins > Page 1630 Electric Assist Choke: Testing and Inspection Procedure 1. Disconnect stator lead at connector leading from choke cap and connect a test light in series with stator lead and ground. 2. With engine running, test light should glow. 3. If light does not glow, repair or replace either the alternator or choke wire. 4. With engine running at normal operating temperature, place test light in series with choke terminal and alternator lead. If light does not glow, replace choke cap assembly. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Adjustments > Automatic Choke Valve Tension Electric Assist Choke: Adjustments Automatic Choke Valve Tension Fig. 10 Automatic choke adjustment Turn thermostatic spring cover against spring tension until index mark on cover is aligned with mark specified in the Specifications Chart on choke housing, Fig. 10. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Electric Assist Choke <--> [Choke Thermostat/Heater] > Component Information > Adjustments > Automatic Choke Valve Tension > Page 1633 Electric Assist Choke: Adjustments Choke Cap Fig. 15 Choke cap adjustment Fig. 15-With choke cap installed, rotate choke cap clockwise until notch on cap is aligned with specified notch on housing. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Dashpot > Component Information > Adjustments Dashpot: Adjustments Fig. 11 Dashpot adjustment With air cleaner removed, and with engine idle speed and mixture properly adjusted, loosen anti-stall dashpot lock nut, Fig. 11. Hold throttle in closed position and depress plunger with a screwdriver. Check clearance between throttle lever and plunger tip with a feeler gauge of the specified clearance dimension. Then turn dashpot in its bracket in a direction to provide the specified clearance. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Rotunda Gas Chek Kit - Requires Modification Fuel: Technical Service Bulletins Rotunda Gas Chek Kit - Requires Modification Article No. FUEL SYSTEM - ROTUNDA "GAS-CHEK" KIT 87-23-9 TOOL MODIFICATION FORD: 1988 And Prior ALL CAR LINES LINCOLN-MERCURY: 1988 And Prior ALL CAR LINES LIGHT TRUCK: 1988 And Prior ALL LIGHT TRUCK LINES ISSUE: The Rotunda "Gas-Chek Kit" (Tool Number 113-00002) that you may have purchased prior to October, 1987 requires modification. The necessary components and new operating instructions will be shipped to you at no charge. This tool modification will provide greater accuracy when performing high fuel vapor pressure testing of gasoline. ACTION: To modify the Rotunda "Gas-Chek Kit", use the following service instructions. NOTE: This modification MUST be done because it will seriously affect the volatility tests. Figure 11 1. Remove adapter fitting attached to the 0-30 PSI gauge. CARE SHOULD BE TAKEN TO PREVENT DAMAGE TO GAUGE ASSEMBLY WHEN REMOVING FITTING. Throw away the adapter fitting, Figure 11. 2. Remove and throw away the aluminum vial, Figure 11. 3. Remove plastic thermos cup cap and throw away, Figure 11. 4. Remove the set of instructions from the lid of the Gas-Chek plastic storage box and throw them away. NOTE: USE ONLY THE NEW instruction booklet that is furnished in the modification kit. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Rotunda Gas Chek Kit - Requires Modification > Page 1641 Figure 12 5. Using thread sealer or teflon tape on the threads of the PSI gauge, install gauge and tighten into new cover and air chamber, Figure 12. After installation is made, this assembly should not be disassembled. 6. Position small, plastic gasoline sample container and gas cup holder into gauge and vial cavity of die-cut, foam material for storage, Figure 12. 7. Care should be taken when storing unit to prevent damage which could then cause bad readings when checking gasoline vapor pressure. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Technical Service Bulletins > Fuel Filter - Replacement Information Fuel Filter: Technical Service Bulletins Fuel Filter - Replacement Information Article No. 85-6-10 FUEL FILTER REPLACEMENT INFORMATION - ALL WITH FUEL FILTERS ATTACHED TO THE CARBURETOR AND/OR FUEL LINE WITH A RUBBER HOSE FORD ALL 1985 AND PRIOR LINCOLN-MERCURY ALL 1985 AND PRIOR LIGHT TRUCK ALL 1985 AND PRIOR New fuel connector hoses and clamps should be used whenever a fuel filter is replaced. Due to possible deterioration of hose materials which may result if a vehicle is fueled with gasoline containing excessive levels of methanol or ethanol, a new fuel hose and clamps should be installed when the fuel filter is changed. DO NOT REUSE OLD HOSES OR CLAMPS. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Service and Repair > Screw In Type Fuel Filter: Service and Repair Screw In Type REMOVAL 1. Remove the air cleaner assembly. 2. Loosen and remove the fuel tube from the filter. 3. Unscrew the filter from the carburetor. INSTALLATION 1. Apply one drop of thread sealer to the external thread of a new filter. Thread the filter into the carburetor inlet port. 2. Tighten the filter to 9.0-11.0 Nm (80-100 in-lbs). 3. Apply ESE-M2C39-E or equivalent oil to the fuel supply tube nut and flare , and hand start the nut into the fuel filter inlet approximately two threads. 4. Use an 11/16 inch wrench on the fuel filter to prevent the filter from rotating. Tighten the fuel filter to supply tube nut to 20-24 Nm (15-18 ft-lb). 5. Install air cleaner assembly. 6. Start the engine and check for fuel leaks. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Component Information > Service and Repair > Screw In Type > Page 1648 Fuel Filter: Service and Repair Inlet Fitting Type REMOVAL - Remove the air cleaner. - Hold the fuel filter inlet hex nut with a backup wrench and unscrew the fuel line tube nut from the fuel filter inlet. WARNING: Use care to prevent combustion from fuel spillage. - Unscrew the fuel inlet fitting. Remove the gasket, filter and spring. - Discard the gasket and filter. INSTALLATION - Install the spring, new filter and gasket. - Hand start the fuel inlet fitting into the carburetor then, tighten to 10-24 Nm (90-125 lb-in). - Apply oil, ESE-M2C39-E or equivalent to the fuel tube nut threads and tube flare. - Hand start the fuel line tube nut into the fuel inlet fitting (approximately two threads). - Use a backup wrench on the fuel inlet fitting while tightening the fuel line tube nut to 20-24 Nm (15-18 lb-ft). - Start the engine and check for fuel leak. - Install the air cleaner. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Hose Clamp > Component Information > Technical Service Bulletins > Fuel Filter - Replacement Information Fuel Hose Clamp: Technical Service Bulletins Fuel Filter - Replacement Information Article No. 85-6-10 FUEL FILTER REPLACEMENT INFORMATION - ALL WITH FUEL FILTERS ATTACHED TO THE CARBURETOR AND/OR FUEL LINE WITH A RUBBER HOSE FORD ALL 1985 AND PRIOR LINCOLN-MERCURY ALL 1985 AND PRIOR LIGHT TRUCK ALL 1985 AND PRIOR New fuel connector hoses and clamps should be used whenever a fuel filter is replaced. Due to possible deterioration of hose materials which may result if a vehicle is fueled with gasoline containing excessive levels of methanol or ethanol, a new fuel hose and clamps should be installed when the fuel filter is changed. DO NOT REUSE OLD HOSES OR CLAMPS. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications SPECIFICATIONS Pressure .............................................................................................................................................. .............................................................. 6.0-8.0 PSI Volume .............................................................. ................................................................................................................................. 1 pint in 20 seconds NOTE: Measurements taken with engine idling. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications > Page 1657 Fuel Pressure: Testing and Inspection PRESSURE TEST 1. Connect a suitable pressure gauge (0-15 PSI) to the carburetor end of the fuel line. WARNING: Use care to prevent combustion of spilled fuel. 2. Start the engine (it should be able to run for over 30 seconds on the fuel in the carburetor bowl) and read the pressure after 10 seconds. If pump pressure is too low or too high install a new fuel pump. Fuel Pump Pressure ............................................................................................................................ ................................................. 6.0-8.0 PSI 3. Reconnect fuel line at filter and install air cleaner. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Technical Service Bulletins > Fuel Hoses - Special Material Fuel Supply Line: Technical Service Bulletins Fuel Hoses - Special Material Article No. 83-4-27 FUEL SYSTEM SPECIAL FUEL HOSE MATERIAL USED WITH ELECTRIC FUEL PUMP SYSTEMS IN OVER 8500 LB. GVW LIGHT TRUCKS - SERVICE REPLACEMENT LIGHT TRUCKS 1980/83 F SERIES AND ECONOLINE Fuel hoses on vehicles equipped with electric fuel pumps are made of a special fluro elastomer material that provides longer life when used in the vapor return system environment. Any service replacement of fuel hoses on these vehicles must use the same type of material. The proper part numbers of these hoses are listed below: ^ 5/16 I.D. Part Number E0TZ-9324-A Stripe Color Yellow ^ 3/8 I.D. Part Number E0TZ-9324-B Stripe Color Red NOTE: Service kits installed to prevent vapor locking on 1980/82 over 8500 lb. GVW E/F Series vehicles also contained fluro elastomer hose and must be serviced with the same service hoses. PART NUMBER PART NAME CLASS E0TZ-9324-A 5/16" Fuel Hose C E0TZ-9324-B 3/8" Fuel Hose C OTHER APPLICABLE ARTICLES: 82-14-21 WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Selector Switch > Component Information > Locations Fuel Tank Selector Switch: Locations LH Side Of I/P Near Fuse Panel Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Switching Valve > Component Information > Technical Service Bulletins > Customer Interest for Fuel Tank Switching Valve: > 831112S > Sep > 84 > Fuel System - Stalls/No Start/Hesitation/ Stumble Fuel Tank Switching Valve: Customer Interest Fuel System - Stalls/No Start/Hesitation/ Stumble Article No. 83-11-12-S STALLS/NO START/HESITATION/ STUMBLE - VAPOR LOCK (5.8L, 6.6L 7.5L) - VEHICLES OVER 8500 LBS. GVW LIGHT TRUCKS 1980/82 E250/350, F250/350 The service part numbers for kits "D" and "E" have been changed from E2UZ-9350-B to E0UZ-9350-D (Kit D) and E2UZ-9350-C to E0UZ-9350-C (Kit E) in TSB 83-11-12. The TSB Article is being reprinted showing the correct part numbers. NOTE: This TSB replaces TSB 82-14-21 dated July 16, 1982 in its entirety. DO NOT attempt to use TSB 82-14-21 to order service parts. Loss of road speed, hesitation, or engine stall on the subject vehicles operated at ambient temperatures over 85~F or at elevations over 4,500 feet, may be the result of fuel vaporization. A modification kit is available for vehicles experiencing this condition. It consists of an in-tank fuel pump, inertia shut-off switch, motorized fuel selector valve, vapor separator, and a vapor return system, along with related fuel lines and electrical wiring and devices. Before this modification is considered, other factors that could result in the same symptoms should be evaluated. Some of these include: ^ Plugged fuel filter at carburetor or tank. ^ Restricted fuel line. ^ Contaminated or low quality fuel. ^ Malfunctioning fuel pump or carburetor. If it is determined that the above factors have not caused the customer concern then the appropriate modification kit should be used to change the fuel system. Hardware Required: Components required to modify the vehicle differ with vehicle series, engine model and type of fuel tank. These have been packaged into 13 different kits. The chart that follows describes the specific kits that are required for the various vehicle configurations. Continued on next page TANK ENGINE (CID) KITS REQUIRED F-Series Single (Midship) 351M/400 A, F, H Single (Plastic Aft Axle) 351M/400 F, C, L Single (Metal Aft Axle) 351M/400 B, F, L Dual (Steel Aft Axle) 351M/400 A, B, F, I Dual (Plastic Aft Axle) 351M/400 A, C, F, I E-Series Single (Aft Axle) 351M/400 D, F, J Dual 351M/400 D, E, F, K E-Series Single (Aft Axle) 7.5L 460 D, G, J Dual 7.5L 460 D, E, G, K KIT SERVICE PART NO. DESCRIPTION CLASS A E2TZ-9350-D Fuel Pump/Sender Kit CG B E2TZ-9350-F Fuel Pump/Sender Kit CG C E2TZ-9350-C Fuel Pump/Sender Kit CG D E0UZ-9350-D Fuel Pump/Sender Kit CG E E0UZ-9350-C Fuel Pump/Sender Kit CG F E0TZ-9B328-A Vapor Separator Kit CG G E0TZ-9B328-B Vapor Separator Kit CG H E2TZ-9A350-H Fuel Line/Electrical Kit CG I E2TZ-9A350-F Fuel Line/Electrical Kit CG J E2UZ-9A350-F Fuel Line/Electrical Kit CG K E2UZ-9A350-D Fuel Line/Electrical Kit CG L E2TZ-9350-G Fuel Line/Electrical Kit CG Select the appropriate kit required; the detailed installation instructions will be supplied with each kit. OTHER APPLICABLE ARTICLES: 83-11-12 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Switching Valve > Component Information > Technical Service Bulletins > Customer Interest for Fuel Tank Switching Valve: > 831112S > Sep > 84 > Fuel System - Stalls/No Start/Hesitation/ Stumble > Page 1674 ARTICLES SUPERSEDED: 82-14-21; 83-11-23 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. DLR. CODING: Basic Part No. 9237 Code: H6 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Switching Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Switching Valve: > 831112S > Sep > 84 > Fuel System - Stalls/No Start/Hesitation/ Stumble Fuel Tank Switching Valve: All Technical Service Bulletins Fuel System - Stalls/No Start/Hesitation/ Stumble Article No. 83-11-12-S STALLS/NO START/HESITATION/ STUMBLE - VAPOR LOCK (5.8L, 6.6L 7.5L) - VEHICLES OVER 8500 LBS. GVW LIGHT TRUCKS 1980/82 E250/350, F250/350 The service part numbers for kits "D" and "E" have been changed from E2UZ-9350-B to E0UZ-9350-D (Kit D) and E2UZ-9350-C to E0UZ-9350-C (Kit E) in TSB 83-11-12. The TSB Article is being reprinted showing the correct part numbers. NOTE: This TSB replaces TSB 82-14-21 dated July 16, 1982 in its entirety. DO NOT attempt to use TSB 82-14-21 to order service parts. Loss of road speed, hesitation, or engine stall on the subject vehicles operated at ambient temperatures over 85~F or at elevations over 4,500 feet, may be the result of fuel vaporization. A modification kit is available for vehicles experiencing this condition. It consists of an in-tank fuel pump, inertia shut-off switch, motorized fuel selector valve, vapor separator, and a vapor return system, along with related fuel lines and electrical wiring and devices. Before this modification is considered, other factors that could result in the same symptoms should be evaluated. Some of these include: ^ Plugged fuel filter at carburetor or tank. ^ Restricted fuel line. ^ Contaminated or low quality fuel. ^ Malfunctioning fuel pump or carburetor. If it is determined that the above factors have not caused the customer concern then the appropriate modification kit should be used to change the fuel system. Hardware Required: Components required to modify the vehicle differ with vehicle series, engine model and type of fuel tank. These have been packaged into 13 different kits. The chart that follows describes the specific kits that are required for the various vehicle configurations. Continued on next page TANK ENGINE (CID) KITS REQUIRED F-Series Single (Midship) 351M/400 A, F, H Single (Plastic Aft Axle) 351M/400 F, C, L Single (Metal Aft Axle) 351M/400 B, F, L Dual (Steel Aft Axle) 351M/400 A, B, F, I Dual (Plastic Aft Axle) 351M/400 A, C, F, I E-Series Single (Aft Axle) 351M/400 D, F, J Dual 351M/400 D, E, F, K E-Series Single (Aft Axle) 7.5L 460 D, G, J Dual 7.5L 460 D, E, G, K KIT SERVICE PART NO. DESCRIPTION CLASS A E2TZ-9350-D Fuel Pump/Sender Kit CG B E2TZ-9350-F Fuel Pump/Sender Kit CG C E2TZ-9350-C Fuel Pump/Sender Kit CG D E0UZ-9350-D Fuel Pump/Sender Kit CG E E0UZ-9350-C Fuel Pump/Sender Kit CG F E0TZ-9B328-A Vapor Separator Kit CG G E0TZ-9B328-B Vapor Separator Kit CG H E2TZ-9A350-H Fuel Line/Electrical Kit CG I E2TZ-9A350-F Fuel Line/Electrical Kit CG J E2UZ-9A350-F Fuel Line/Electrical Kit CG K E2UZ-9A350-D Fuel Line/Electrical Kit CG L E2TZ-9350-G Fuel Line/Electrical Kit CG Select the appropriate kit required; the detailed installation instructions will be supplied with each kit. OTHER APPLICABLE ARTICLES: 83-11-12 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Switching Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Tank Switching Valve: > 831112S > Sep > 84 > Fuel System - Stalls/No Start/Hesitation/ Stumble > Page 1680 ARTICLES SUPERSEDED: 82-14-21; 83-11-23 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. DLR. CODING: Basic Part No. 9237 Code: H6 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Tank Switching Valve > Component Information > Technical Service Bulletins > Page 1681 Fuel Tank Switching Valve: Locations Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Mechanical > Idle Speed Vacuum Solenoid Valve > Component Information > Locations > Throttle Kicker Vacuum Valve Idle Speed Vacuum Solenoid Valve: Locations Throttle Kicker Vacuum Valve RH Side Of V8-460/7. Top Of 8 Cyl. Engine, LH Side of 6 Cyl. Engine Applicable to: 5L Engine Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Mechanical > Idle Speed Vacuum Solenoid Valve > Component Information > Locations > Throttle Kicker Vacuum Valve > Page 1687 Idle Speed Vacuum Solenoid Valve: Locations Throttle Kicker Solenoid LH Side Of 6-300/4. Attached to LH Valve Cover Applicable to: 9L Engine Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle/Altitude Compensator (Non Comp. Controlled) > Component Information > Description and Operation > Altitude Compensator Idle/Altitude Compensator (Non Comp. Controlled): Description and Operation Altitude Compensator Fig. 7 Electrical type altitude compensator ELECTRICAL The electrical type altitude compensator, Fig. 7, used on some vehicles, is mounted on the ignition module. The compensator improves emissions and aids engine performance at altitudes above 4000 ft. by advancing the timing and leaning the air/fuel mixture. Fig. 8 Mechanical type altitude compensator MECHANICAL The mechanical type altitude compensator, Fig. 8, is mounted on the bulkhead. The compensator leans the air/fuel mixture at altitudes above 3000 ft. by supplying additional filtered air to the carburetor. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle/Altitude Compensator (Non Comp. Controlled) > Component Information > Description and Operation > Altitude Compensator > Page 1692 Idle/Altitude Compensator (Non Comp. Controlled): Description and Operation Hot Idle Compensator Fig. 17 Hot idle compensator The hot idle compensator, Fig. 17, used on some vehicles, cools the engine during hot idle operation. The compensator may be integral with the carburetor or mounted separately. When open, the compensator bleeds air into the manifold, leaning out the air/fuel mixture at idle. This increased air intake causes an increase in engine idle speed, resulting in cooling of the engine. Temperature rise on the bi-metal sensor lifts the normally closed valve and opens the air passage. A valve that does not fully close will cause high idle speed and excessive exhaust emission. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle/Altitude Compensator (Non Comp. Controlled) > Component Information > Description and Operation > Page 1693 Idle/Altitude Compensator (Non Comp. Controlled): Testing and Inspection ELECTRICAL 1. Check and record engine timing. 2. Disconnect compensator from ignition module and connect suitable jumper wire across module connectors. Recheck engine timing. 3. At altitudes of 4000 ft. or lower, timing should be advanced 4° on V8-302 engine, or 6° on V8-351 engine. 4. At altitudes of 4000 ft. or higher on 6-300 engine, or 4600 ft. or more on V8-302 and V8-351 engines, there should be no change in timing. Fig. 8 Mechanical type altitude compensator MECHANICAL 1. Connect a suitable vacuum gauge to air inlet nipple, Fig. 8, and check for vacuum with engine running. 2. On 4-140 engine, there should be no vacuum at altitudes of 2500 ft. or lower and vacuum should be present at altitudes of 3000 ft. or higher. 3. On V6-232 engines, there should be no vacuum at altitudes of 3500 ft. or lower and vacuum should be present at altitudes of 4000 ft. or higher. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pump Inertia Switch: > 831112S > Sep > 84 > Fuel System - Stalls/No Start/Hesitation/ Stumble Fuel Pump Inertia Switch: Customer Interest Fuel System - Stalls/No Start/Hesitation/ Stumble Article No. 83-11-12-S STALLS/NO START/HESITATION/ STUMBLE - VAPOR LOCK (5.8L, 6.6L 7.5L) - VEHICLES OVER 8500 LBS. GVW LIGHT TRUCKS 1980/82 E250/350, F250/350 The service part numbers for kits "D" and "E" have been changed from E2UZ-9350-B to E0UZ-9350-D (Kit D) and E2UZ-9350-C to E0UZ-9350-C (Kit E) in TSB 83-11-12. The TSB Article is being reprinted showing the correct part numbers. NOTE: This TSB replaces TSB 82-14-21 dated July 16, 1982 in its entirety. DO NOT attempt to use TSB 82-14-21 to order service parts. Loss of road speed, hesitation, or engine stall on the subject vehicles operated at ambient temperatures over 85~F or at elevations over 4,500 feet, may be the result of fuel vaporization. A modification kit is available for vehicles experiencing this condition. It consists of an in-tank fuel pump, inertia shut-off switch, motorized fuel selector valve, vapor separator, and a vapor return system, along with related fuel lines and electrical wiring and devices. Before this modification is considered, other factors that could result in the same symptoms should be evaluated. Some of these include: ^ Plugged fuel filter at carburetor or tank. ^ Restricted fuel line. ^ Contaminated or low quality fuel. ^ Malfunctioning fuel pump or carburetor. If it is determined that the above factors have not caused the customer concern then the appropriate modification kit should be used to change the fuel system. Hardware Required: Components required to modify the vehicle differ with vehicle series, engine model and type of fuel tank. These have been packaged into 13 different kits. The chart that follows describes the specific kits that are required for the various vehicle configurations. Continued on next page TANK ENGINE (CID) KITS REQUIRED F-Series Single (Midship) 351M/400 A, F, H Single (Plastic Aft Axle) 351M/400 F, C, L Single (Metal Aft Axle) 351M/400 B, F, L Dual (Steel Aft Axle) 351M/400 A, B, F, I Dual (Plastic Aft Axle) 351M/400 A, C, F, I E-Series Single (Aft Axle) 351M/400 D, F, J Dual 351M/400 D, E, F, K E-Series Single (Aft Axle) 7.5L 460 D, G, J Dual 7.5L 460 D, E, G, K KIT SERVICE PART NO. DESCRIPTION CLASS A E2TZ-9350-D Fuel Pump/Sender Kit CG B E2TZ-9350-F Fuel Pump/Sender Kit CG C E2TZ-9350-C Fuel Pump/Sender Kit CG D E0UZ-9350-D Fuel Pump/Sender Kit CG E E0UZ-9350-C Fuel Pump/Sender Kit CG F E0TZ-9B328-A Vapor Separator Kit CG G E0TZ-9B328-B Vapor Separator Kit CG H E2TZ-9A350-H Fuel Line/Electrical Kit CG I E2TZ-9A350-F Fuel Line/Electrical Kit CG J E2UZ-9A350-F Fuel Line/Electrical Kit CG K E2UZ-9A350-D Fuel Line/Electrical Kit CG L E2TZ-9350-G Fuel Line/Electrical Kit CG Select the appropriate kit required; the detailed installation instructions will be supplied with each kit. OTHER APPLICABLE ARTICLES: 83-11-12 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pump Inertia Switch: > 831112S > Sep > 84 > Fuel System - Stalls/No Start/Hesitation/ Stumble > Page 1702 ARTICLES SUPERSEDED: 82-14-21; 83-11-23 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. DLR. CODING: Basic Part No. 9237 Code: H6 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pump Inertia Switch: > 831112S > Sep > 84 > Fuel System - Stalls/No Start/Hesitation/ Stumble Fuel Pump Inertia Switch: All Technical Service Bulletins Fuel System - Stalls/No Start/Hesitation/ Stumble Article No. 83-11-12-S STALLS/NO START/HESITATION/ STUMBLE - VAPOR LOCK (5.8L, 6.6L 7.5L) - VEHICLES OVER 8500 LBS. GVW LIGHT TRUCKS 1980/82 E250/350, F250/350 The service part numbers for kits "D" and "E" have been changed from E2UZ-9350-B to E0UZ-9350-D (Kit D) and E2UZ-9350-C to E0UZ-9350-C (Kit E) in TSB 83-11-12. The TSB Article is being reprinted showing the correct part numbers. NOTE: This TSB replaces TSB 82-14-21 dated July 16, 1982 in its entirety. DO NOT attempt to use TSB 82-14-21 to order service parts. Loss of road speed, hesitation, or engine stall on the subject vehicles operated at ambient temperatures over 85~F or at elevations over 4,500 feet, may be the result of fuel vaporization. A modification kit is available for vehicles experiencing this condition. It consists of an in-tank fuel pump, inertia shut-off switch, motorized fuel selector valve, vapor separator, and a vapor return system, along with related fuel lines and electrical wiring and devices. Before this modification is considered, other factors that could result in the same symptoms should be evaluated. Some of these include: ^ Plugged fuel filter at carburetor or tank. ^ Restricted fuel line. ^ Contaminated or low quality fuel. ^ Malfunctioning fuel pump or carburetor. If it is determined that the above factors have not caused the customer concern then the appropriate modification kit should be used to change the fuel system. Hardware Required: Components required to modify the vehicle differ with vehicle series, engine model and type of fuel tank. These have been packaged into 13 different kits. The chart that follows describes the specific kits that are required for the various vehicle configurations. Continued on next page TANK ENGINE (CID) KITS REQUIRED F-Series Single (Midship) 351M/400 A, F, H Single (Plastic Aft Axle) 351M/400 F, C, L Single (Metal Aft Axle) 351M/400 B, F, L Dual (Steel Aft Axle) 351M/400 A, B, F, I Dual (Plastic Aft Axle) 351M/400 A, C, F, I E-Series Single (Aft Axle) 351M/400 D, F, J Dual 351M/400 D, E, F, K E-Series Single (Aft Axle) 7.5L 460 D, G, J Dual 7.5L 460 D, E, G, K KIT SERVICE PART NO. DESCRIPTION CLASS A E2TZ-9350-D Fuel Pump/Sender Kit CG B E2TZ-9350-F Fuel Pump/Sender Kit CG C E2TZ-9350-C Fuel Pump/Sender Kit CG D E0UZ-9350-D Fuel Pump/Sender Kit CG E E0UZ-9350-C Fuel Pump/Sender Kit CG F E0TZ-9B328-A Vapor Separator Kit CG G E0TZ-9B328-B Vapor Separator Kit CG H E2TZ-9A350-H Fuel Line/Electrical Kit CG I E2TZ-9A350-F Fuel Line/Electrical Kit CG J E2UZ-9A350-F Fuel Line/Electrical Kit CG K E2UZ-9A350-D Fuel Line/Electrical Kit CG L E2TZ-9350-G Fuel Line/Electrical Kit CG Select the appropriate kit required; the detailed installation instructions will be supplied with each kit. OTHER APPLICABLE ARTICLES: 83-11-12 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pump Inertia Switch: > 831112S > Sep > 84 > Fuel System - Stalls/No Start/Hesitation/ Stumble > Page 1708 ARTICLES SUPERSEDED: 82-14-21; 83-11-23 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. DLR. CODING: Basic Part No. 9237 Code: H6 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations RH Fender Apron w/EEC Attached To Top Of RH Fender Apron Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations RH Fender Apron w/EEC Attached To Top Of RH Fender Apron Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Tank Selector Switch > Component Information > Locations Fuel Tank Selector Switch: Locations LH Side Of I/P Near Fuse Panel Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pump Inertia Switch: > 831112S > Sep > 84 > Fuel System Stalls/No Start/Hesitation/ Stumble Fuel Pump Inertia Switch: Customer Interest Fuel System - Stalls/No Start/Hesitation/ Stumble Article No. 83-11-12-S STALLS/NO START/HESITATION/ STUMBLE - VAPOR LOCK (5.8L, 6.6L 7.5L) - VEHICLES OVER 8500 LBS. GVW LIGHT TRUCKS 1980/82 E250/350, F250/350 The service part numbers for kits "D" and "E" have been changed from E2UZ-9350-B to E0UZ-9350-D (Kit D) and E2UZ-9350-C to E0UZ-9350-C (Kit E) in TSB 83-11-12. The TSB Article is being reprinted showing the correct part numbers. NOTE: This TSB replaces TSB 82-14-21 dated July 16, 1982 in its entirety. DO NOT attempt to use TSB 82-14-21 to order service parts. Loss of road speed, hesitation, or engine stall on the subject vehicles operated at ambient temperatures over 85~F or at elevations over 4,500 feet, may be the result of fuel vaporization. A modification kit is available for vehicles experiencing this condition. It consists of an in-tank fuel pump, inertia shut-off switch, motorized fuel selector valve, vapor separator, and a vapor return system, along with related fuel lines and electrical wiring and devices. Before this modification is considered, other factors that could result in the same symptoms should be evaluated. Some of these include: ^ Plugged fuel filter at carburetor or tank. ^ Restricted fuel line. ^ Contaminated or low quality fuel. ^ Malfunctioning fuel pump or carburetor. If it is determined that the above factors have not caused the customer concern then the appropriate modification kit should be used to change the fuel system. Hardware Required: Components required to modify the vehicle differ with vehicle series, engine model and type of fuel tank. These have been packaged into 13 different kits. The chart that follows describes the specific kits that are required for the various vehicle configurations. Continued on next page TANK ENGINE (CID) KITS REQUIRED F-Series Single (Midship) 351M/400 A, F, H Single (Plastic Aft Axle) 351M/400 F, C, L Single (Metal Aft Axle) 351M/400 B, F, L Dual (Steel Aft Axle) 351M/400 A, B, F, I Dual (Plastic Aft Axle) 351M/400 A, C, F, I E-Series Single (Aft Axle) 351M/400 D, F, J Dual 351M/400 D, E, F, K E-Series Single (Aft Axle) 7.5L 460 D, G, J Dual 7.5L 460 D, E, G, K KIT SERVICE PART NO. DESCRIPTION CLASS A E2TZ-9350-D Fuel Pump/Sender Kit CG B E2TZ-9350-F Fuel Pump/Sender Kit CG C E2TZ-9350-C Fuel Pump/Sender Kit CG D E0UZ-9350-D Fuel Pump/Sender Kit CG E E0UZ-9350-C Fuel Pump/Sender Kit CG F E0TZ-9B328-A Vapor Separator Kit CG G E0TZ-9B328-B Vapor Separator Kit CG H E2TZ-9A350-H Fuel Line/Electrical Kit CG I E2TZ-9A350-F Fuel Line/Electrical Kit CG J E2UZ-9A350-F Fuel Line/Electrical Kit CG K E2UZ-9A350-D Fuel Line/Electrical Kit CG L E2TZ-9350-G Fuel Line/Electrical Kit CG Select the appropriate kit required; the detailed installation instructions will be supplied with each kit. OTHER APPLICABLE ARTICLES: 83-11-12 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pump Inertia Switch: > 831112S > Sep > 84 > Fuel System Stalls/No Start/Hesitation/ Stumble > Page 1728 ARTICLES SUPERSEDED: 82-14-21; 83-11-23 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. DLR. CODING: Basic Part No. 9237 Code: H6 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pump Inertia Switch: > 831112S > Sep > 84 > Fuel System - Stalls/No Start/Hesitation/ Stumble Fuel Pump Inertia Switch: All Technical Service Bulletins Fuel System - Stalls/No Start/Hesitation/ Stumble Article No. 83-11-12-S STALLS/NO START/HESITATION/ STUMBLE - VAPOR LOCK (5.8L, 6.6L 7.5L) - VEHICLES OVER 8500 LBS. GVW LIGHT TRUCKS 1980/82 E250/350, F250/350 The service part numbers for kits "D" and "E" have been changed from E2UZ-9350-B to E0UZ-9350-D (Kit D) and E2UZ-9350-C to E0UZ-9350-C (Kit E) in TSB 83-11-12. The TSB Article is being reprinted showing the correct part numbers. NOTE: This TSB replaces TSB 82-14-21 dated July 16, 1982 in its entirety. DO NOT attempt to use TSB 82-14-21 to order service parts. Loss of road speed, hesitation, or engine stall on the subject vehicles operated at ambient temperatures over 85~F or at elevations over 4,500 feet, may be the result of fuel vaporization. A modification kit is available for vehicles experiencing this condition. It consists of an in-tank fuel pump, inertia shut-off switch, motorized fuel selector valve, vapor separator, and a vapor return system, along with related fuel lines and electrical wiring and devices. Before this modification is considered, other factors that could result in the same symptoms should be evaluated. Some of these include: ^ Plugged fuel filter at carburetor or tank. ^ Restricted fuel line. ^ Contaminated or low quality fuel. ^ Malfunctioning fuel pump or carburetor. If it is determined that the above factors have not caused the customer concern then the appropriate modification kit should be used to change the fuel system. Hardware Required: Components required to modify the vehicle differ with vehicle series, engine model and type of fuel tank. These have been packaged into 13 different kits. The chart that follows describes the specific kits that are required for the various vehicle configurations. Continued on next page TANK ENGINE (CID) KITS REQUIRED F-Series Single (Midship) 351M/400 A, F, H Single (Plastic Aft Axle) 351M/400 F, C, L Single (Metal Aft Axle) 351M/400 B, F, L Dual (Steel Aft Axle) 351M/400 A, B, F, I Dual (Plastic Aft Axle) 351M/400 A, C, F, I E-Series Single (Aft Axle) 351M/400 D, F, J Dual 351M/400 D, E, F, K E-Series Single (Aft Axle) 7.5L 460 D, G, J Dual 7.5L 460 D, E, G, K KIT SERVICE PART NO. DESCRIPTION CLASS A E2TZ-9350-D Fuel Pump/Sender Kit CG B E2TZ-9350-F Fuel Pump/Sender Kit CG C E2TZ-9350-C Fuel Pump/Sender Kit CG D E0UZ-9350-D Fuel Pump/Sender Kit CG E E0UZ-9350-C Fuel Pump/Sender Kit CG F E0TZ-9B328-A Vapor Separator Kit CG G E0TZ-9B328-B Vapor Separator Kit CG H E2TZ-9A350-H Fuel Line/Electrical Kit CG I E2TZ-9A350-F Fuel Line/Electrical Kit CG J E2UZ-9A350-F Fuel Line/Electrical Kit CG K E2UZ-9A350-D Fuel Line/Electrical Kit CG L E2TZ-9350-G Fuel Line/Electrical Kit CG Select the appropriate kit required; the detailed installation instructions will be supplied with each kit. OTHER APPLICABLE ARTICLES: 83-11-12 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pump Inertia Switch: > 831112S > Sep > 84 > Fuel System - Stalls/No Start/Hesitation/ Stumble > Page 1734 ARTICLES SUPERSEDED: 82-14-21; 83-11-23 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. DLR. CODING: Basic Part No. 9237 Code: H6 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications THROTTLE POSITION SENSOR SPECIFICATIONS Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 1738 Throttle Position Sensor: Description and Operation Fig. 2 Throttle position sensor (typical) This sensor, Fig. 2, is basically a rheostat switch attached to the carburetor throttle shaft and responds to throttle valve angle changes. The throttle angles are classified into three operating modes as follows: a. Closed Throttle (Idle or Deceleration) b. Part Throttle c. Wide Open Throttle (Maximum Acceleration) The ECA applies a reference voltage of about 9 volts to the sensor. The resultant sensor voltage supplied to the ECA, which is determined by the throttle position, is used by the ECA to determine the proper amount of spark advance, EGR flow, air/fuel ratio and thermactor air mode. The throttle position sensor mounting holes are slotted to permit adjustment. If the sensor is replaced, it must be correctly positioned or incorrect throttle information will be sent to the ECA. The adjustment requires use of special electronic test equipment. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 1739 Throttle Position Sensor: Adjustments Engines with EEC III Turn ignition to RUN position and remove vacuum hose from throttle kicker, as equipped. With engine not running, compare voltage reading against specifications and adjust as needed. Engines with EEC IV Connect positive probe of DVOM along terminal C (lower) of TPS and connect negative probe along terminal A (upper). Turn ignition on but do not start vehicle. Adjust TPS to specified value. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > Customer Interest for Throttle Cable/Linkage: > 83720 > Apr > 83 > Accelerator Linkage - Raspy/Sticky Throttle Cable/Linkage: Customer Interest Accelerator Linkage - Raspy/Sticky Article No. 83-7-20 ACCELERATOR LINKAGE - DIAGNOSTIC PROCEDURE LIGHT TRUCKS 1980-83 LIGHT TRUCKS Servicing of Cable-Type Acceleration Linkage The following procedure will assist in diagnosing accelerator linkage concerns on 1980-83 light trucks. If the accelerator pedal, when operated, is hard to push down or feels "raspy" or "sticky", perform the following: 1. First disconnect the accelerator cable from the carburetor (or injector pump) throttle lever ball stud. Also disconnect the cruise control from the accelerator cable if so equipped. 2. Then check the following items: ^ Be sure that the disconnected end of the cable or its spring does not come into contact with any of the surrounding parts. ^ Operate the pedal by foot. ^ If accelerator operation is smooth, the pedal assembly and cable are not the cause of the concern. Refer to the carburetor/injector pump diagnosis procedures in the appropriate shop manual for additional checks. ^ E, F, Bronco and Ranger with gas engine - See General Fuel System Service Section 24-01. ^ Ranger with Diesel Engine - See Ranger Shop Manual - 2.2L Diesel Engine Section 22-09 of the Engine Performance Diagnostic Guide. ^ F Series with the 6.9L Diesel Engine - See the 1983 Car/Truck Shop Manual - Engine Electronics Section 25-64. ^ If the concern persists (being sure disconnected end of cable has not come into contact with anything), check foot pedal assembly for free operation. If pedal operation is free, replace the cable. If you have a high engine idle speed concern, check the following linkage systems: 1. First disconnect the accelerator cable from the carburetor (or injector pump) throttle lever ball stud. Also disconnect the cruise control from the accelerator cable if so equipped. ^ If the cable ball socket extends beyond the throttle lever ball stud, refer to the carburetor diagnosis procedures in the appropriate shop manual for the correct adjustment procedure. ^ If the socket does not extend beyond the stud, check the foot pedal assembly for free operation. If the pedal operation is free, replace the cable. NOTE: The accelerator cable should not be lubricated and it is not serviceable. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: M TIME: "Actual Time" as defined in the Warranty and Policy Manual. DLR. CODING: Basic Part No. 9A758 Code: 41 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Cable/Linkage: > 83720 > Apr > 83 > Accelerator Linkage - Raspy/Sticky Throttle Cable/Linkage: All Technical Service Bulletins Accelerator Linkage - Raspy/Sticky Article No. 83-7-20 ACCELERATOR LINKAGE - DIAGNOSTIC PROCEDURE LIGHT TRUCKS 1980-83 LIGHT TRUCKS Servicing of Cable-Type Acceleration Linkage The following procedure will assist in diagnosing accelerator linkage concerns on 1980-83 light trucks. If the accelerator pedal, when operated, is hard to push down or feels "raspy" or "sticky", perform the following: 1. First disconnect the accelerator cable from the carburetor (or injector pump) throttle lever ball stud. Also disconnect the cruise control from the accelerator cable if so equipped. 2. Then check the following items: ^ Be sure that the disconnected end of the cable or its spring does not come into contact with any of the surrounding parts. ^ Operate the pedal by foot. ^ If accelerator operation is smooth, the pedal assembly and cable are not the cause of the concern. Refer to the carburetor/injector pump diagnosis procedures in the appropriate shop manual for additional checks. ^ E, F, Bronco and Ranger with gas engine - See General Fuel System Service Section 24-01. ^ Ranger with Diesel Engine - See Ranger Shop Manual - 2.2L Diesel Engine Section 22-09 of the Engine Performance Diagnostic Guide. ^ F Series with the 6.9L Diesel Engine - See the 1983 Car/Truck Shop Manual - Engine Electronics Section 25-64. ^ If the concern persists (being sure disconnected end of cable has not come into contact with anything), check foot pedal assembly for free operation. If pedal operation is free, replace the cable. If you have a high engine idle speed concern, check the following linkage systems: 1. First disconnect the accelerator cable from the carburetor (or injector pump) throttle lever ball stud. Also disconnect the cruise control from the accelerator cable if so equipped. ^ If the cable ball socket extends beyond the throttle lever ball stud, refer to the carburetor diagnosis procedures in the appropriate shop manual for the correct adjustment procedure. ^ If the socket does not extend beyond the stud, check the foot pedal assembly for free operation. If the pedal operation is free, replace the cable. NOTE: The accelerator cable should not be lubricated and it is not serviceable. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: M TIME: "Actual Time" as defined in the Warranty and Policy Manual. DLR. CODING: Basic Part No. 9A758 Code: 41 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications THROTTLE POSITION SENSOR SPECIFICATIONS Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 1756 Throttle Position Sensor: Description and Operation Fig. 2 Throttle position sensor (typical) This sensor, Fig. 2, is basically a rheostat switch attached to the carburetor throttle shaft and responds to throttle valve angle changes. The throttle angles are classified into three operating modes as follows: a. Closed Throttle (Idle or Deceleration) b. Part Throttle c. Wide Open Throttle (Maximum Acceleration) The ECA applies a reference voltage of about 9 volts to the sensor. The resultant sensor voltage supplied to the ECA, which is determined by the throttle position, is used by the ECA to determine the proper amount of spark advance, EGR flow, air/fuel ratio and thermactor air mode. The throttle position sensor mounting holes are slotted to permit adjustment. If the sensor is replaced, it must be correctly positioned or incorrect throttle information will be sent to the ECA. The adjustment requires use of special electronic test equipment. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 1757 Throttle Position Sensor: Adjustments Engines with EEC III Turn ignition to RUN position and remove vacuum hose from throttle kicker, as equipped. With engine not running, compare voltage reading against specifications and adjust as needed. Engines with EEC IV Connect positive probe of DVOM along terminal C (lower) of TPS and connect negative probe along terminal A (upper). Turn ignition on but do not start vehicle. Adjust TPS to specified value. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > With EEC III Firing Order: Specifications With EEC III With EEC III The cylinders are numbered 1-4 on the Right side, starting with the front, and 5-8 on the left side, ending with the rear. Because of the unique dual level rotor used by the EEC-III Ignition system, the engine's firing order cannot be read off the top of Firing Order 1-3-7-2-6-5-4-8 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications > With EEC III > Page 1763 Firing Order: Specifications Without EEC III Without EEC III Firing Order 1-3-7-2-6-5-4-8 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Ignition Timing Connector > Component Information > Description and Operation Ignition Timing Connector: Description and Operation Fig. 20 Ignition Timing Vacuum Switch Below vacuum setting, this switch, Fig. 20, used on some vehicles, is open and signals the ignition module to retard spark timing. The switch is closed above the vacuum setting and the ignition module is in the non-retard spark timing mode. Calibration resistors inside the switch control the amount of retard. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Ignition Timing Connector > Component Information > Description and Operation > Page 1768 Ignition Timing Connector: Testing and Inspection Ignition Timing Vacuum Switch Ignition Timing Vacuum Switch Test Chart 1. Disconnect switch from ignition module. 2. Connect suitable ohmmeter across switch terminals and compare resistance measured to ``less than'' values in the Ignition Timing vacuum Switch Test chart. 3. Apply vacuum to switch, using an outside vacuum source. Compare resistance now measured across switch terminals to ``greater than'' values in the Ignition Timing vacuum Switch Test chart. 4. Replace switch if resistance is not within specifications. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations > With Electronic Engine Controls (EEC) Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations > With Electronic Engine Controls (EEC) > Page 1773 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Timing Marks and Indicators > System Information > Diagrams Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Resistor <--> [Ignition Ballast Resistor] > Component Information > Description and Operation Ignition Resistor: Description and Operation The ballast resistor, (wire type), maintains a specific resistance between the positive (Batt.) terminal of the ignition coil connector and the wiring harness connector. It is not in operation during engine cranking enabling the coil to receive a hotter signal for starting. Once the engine is running, the resistor is used to protect the coil from voltage overload. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Resistor <--> [Ignition Ballast Resistor] > Component Information > Description and Operation > Page 1780 Ignition Resistor: Testing and Inspection 1. Disconnect module connector with red and white wires then, ignition coil connector. 2. Using a suitable ohmmeter, measure resistance between Batt. terminal of ignition coil connector and wiring harness connector wire that joins red wire in module connector. 3. If resistance is 0.8---1.6 ohms, ballast resistor is satisfactory. If resistance is less than 0.8 ohms or greater than 1.6 ohms, replace ballast resistor. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications CRANKSHAFT SENSOR Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 1784 Crankshaft Position Sensor: Locations RH Front Of Engine Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 1785 Crankshaft Position Sensor: Description and Operation Fig.6 - Crankshaft Position Sensor Fig.7 - Crankshaft Position Sensor DESCRIPTION The crankshaft vibration damper is fitted with a four-lobe "pulse ring" which provides the system with an accurate indication of when the pistons reach 10 BTDC. This indication is called the reference timing. Figs. 6 and 7. The pulse ring is a powdered metal ring positioned on the crankshaft vibration damper during manufacture. It has four equally spaced lobes which represent crankshaft position when the pistons reach 10 BTDC. During operation, the lobes on the pulse ring pass by the tip of the CP sensor. The pulse ring interrupts the magnetic field at the tip of the sensor. When the field is interrupted, an output signal is generated and sent to the ECA. As the crankshaft turns, the ECA evaluates the electrical impulses to determine the exact position of the crankshaft at any given time. By the frequency of the impulses, the ECA can determine the engine speed. With these two factors, the ECA will determine the appropriate ignition timing advance required for best engine operation. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Advance Unit > Component Information > Specifications DISTRIBUTOR TIMING ADVANCE Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Advance Unit > Component Information > Description and Operation > Vacuum Spark Advance Mechanism Distributor Advance Unit: Description and Operation Vacuum Spark Advance Mechanism The vacuum spark control mechanism can provide spark advance if a single diaphragm assembly is used or spark advance and retard if a dual diaphragm assembly is used. The diaphragm assembly used depends on the engine calibration. Single Diaphragm Assembly SINGLE DIAPHRAGM ASSEMBLY The single diaphragm assembly, Fig. 11, also changes the armature to stator relationship to give spark advance. The stator assembly position is changed by means of vacuum being applied to the diaphragm assembly. Vacuum applied to the diaphragm assembly causes the diaphragm and attached diaphragm rod to move, compressing the advance spring, which controls the rate of advance. The movement of the diaphragm rod, which is attached to the stator assembly, makes the the stator assembly move with respect to the armature. This changes the initial armature to stator relationship set during initial timing, causing spark advance. The stator assembly is mounted on the lower plate assembly which with the diaphragm assembly, is attached to the distributor base. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Advance Unit > Component Information > Description and Operation > Vacuum Spark Advance Mechanism > Page 1792 Dual Diaphragm Assembly DUAL DIAPHRAGM ASSEMBLY The dual diaphragm assembly, Fig. 12, obtains spark advance in the same manner as the single diaphragm assembly. In this case vacuum applied to the vacuum advance port causes the advance diaphragm and attached rod to move, otherwise the action is the same. Spark retard is done by applying vacuum to the vacuum retard port. This causes the retard diaphragm to move, compressing the retard spring, which controls the rate of spark retard. Compressing the retard spring allows the diaphragm rod stop to move due to the force applied by the advance spring pushing against it by means of the diaphragm rod. The result is the diaphragm rod moves causing the attached stator assembly to change position with respect to the armature. In this instance the direction of the stator assembly movement is opposite that occurring during vacuum advance, resulting in spark retard. NOTE: Any vacuum applied to the advance port overrides any spark retard caused by vacuum being applied to the retard port. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Advance Unit > Component Information > Description and Operation > Vacuum Spark Advance Mechanism > Page 1793 Distributor Advance Unit: Description and Operation Centrifugal Spark Advance Mechanism Distributor - Exploded view The centrifugal advance mechanism varies the relationship of the armature to the stator assembly. The armature is mounted to the sleeve and plate assembly which rotates in relation to the distributor shaft. The rotation is a result of the centrifugal weights moving in response to engine RPM. The movement of the weights change the initial relationship of the armature to the stator assembly by rotating the sleeve and plate assembly ahead of its static position on the distributor shaft Fig. 1. This produces spark advance. The rate of movement of the weights is controlled by calibrated springs. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Advance Unit > Component Information > Description and Operation > Page 1794 Distributor Advance Unit: Service and Repair 1. Remove distributor cap and rotor. 2. Disconnect vacuum lines, then remove snap ring that secures vacuum advance link to pickup assembly. 3. Remove vacuum advance attaching screws, then tilt unit downward to disconnect link. 4. Carefully remove unit from distributor. 5. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Retard Control > Component Information > Locations Distributor Retard Control: Locations Below Vacuum Switch Between No. 5 & No. 6 Spark Plugs Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Vacuum Control > Component Information > Description and Operation Distributor Vacuum Control: Description and Operation 3-Port Vacuum Regulator Vacuum Regulator (3 & 4 Port) Three port, Fig. 27, regulators and four port, Fig. 28, regulators are used to control the vacuum advance to the distributor. During engine idle conditions, the manifold vacuum signal is reduced to a constant output signal. Off idle, the output signal equals the spark port. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Vacuum Control > Component Information > Testing and Inspection > Distributor Modulator Valve Assembly Distributor Vacuum Control: Testing and Inspection Distributor Modulator Valve Assembly 1. Turn ignition key to ``ON'' and check resistance at solenoid terminals. 2. If solenoid resistance is not 51---108 ohms, replace solenoid. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Vacuum Control > Component Information > Testing and Inspection > Distributor Modulator Valve Assembly > Page 1803 Distributor Vacuum Control: Testing and Inspection Vacuum Regulator Procedure 1. Disconnect vacuum line from distributor port and connect a vacuum gauge. 2. With engine at idle, the vacuum gauge reading should be within 1 inch Hg. vacuum of the calibration point. The calibration point of each valve can be identified according to color code as follows: Black, 6 inches Hg.; green, 7 inches Hg.; red, 8 inches Hg. 3. Replace valve if not within specifications. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > Ignition Rotor - Alignment Procedure Ignition Rotor: Technical Service Bulletins Ignition Rotor - Alignment Procedure Article No. 83-8-14 EEC III/DISTRIBUTOR - PROCEDURE FOR SETTING ROTOR ALIGNMENT 5.0L/5.8L EEC EQUIPPED LIGHT TRUCKS LIGHT TRUCKS 1981/83 BRONCO, F-SERIES AND ECONOLINE The following information and procedures are issued to clarify the proper setting of distributor rotor alignment on the subject vehicles. This reference publication supersedes all other printed material on subject. FIGURE 12 FIGURE 13 For 1981 through 1983 model year vehicles, EEC distributors used on the EEC Systems had the "second generation" rotor (Figure 12). The 1983 model 5.0L EEC equipped Light Truck employs a conventional rotor (Figure 13). PROCEDURE FOR ROTOR ALIGNMENT: 1. Remove the distributor cap and wires and position them to one side. 2. Remove the rotor. 3. To check rotor alignment: a. Rotate the engine until the No. 1 piston is on the compression stroke. NOTE: Verification of being on the compression stroke is essential to correct rotor alignment. If the piston is on the exhaust stroke, the rotor can be misaligned by 180~. b. Slowly rotate the engine until the alignment tool can be installed. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > Ignition Rotor - Alignment Procedure > Page 1808 FIGURE 14 c. The T79P-12200-A tool mounts between the slot on the sleeve and the slot (cut out) on the adapter (Figure 14). d. Read the timing mark on the damper indicated by the timing pointer. e. If the timing mark is specification, TDC +/- 4~, the rotor alignment is satisfactory. The alignment tool can be removed. TO ADJUST ROTOR ALIGNMENT: 1. Remove the distributor cap by loosening the two spring clips holding the cap of the distributor adapter. Remove rotor. 2. Rotate engine until No. 1 piston is on the compression stroke. (See Step 3a above). 3. Slowly rotate the engine until the timing pointer is aligned with the specified timing mark. (TDC +/- 4~). 4. Loosen the two sleeve assembly adjustment screws and rotate the sleeve until the alignment tool T79PFIGURE 14 12200-A fits into the alignment slots on the sleeve and the adapter (Figure 14). 5. Tighten the adjustment screw to 2.8-3.9 N-m (25-30 lb.in.). Remove alignment tool. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Ignition Rotor > Component Information > Technical Service Bulletins > Ignition Rotor - Alignment Procedure > Page 1809 FIGURE 13 6. If the vehicle is a 1983 model equipped with a 5.0L engine, coat the rotor with silicone grease as shown in Figure 13. 7. Reinstall distributor cap and rotor making sure wires are firmly seated in the distributor cap terminal housings and on the spark plugs. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Distributor Plate W/ Pick-up Sensor > Component Information > Service and Repair Distributor Plate W/ Pick-up Sensor: Service and Repair 1. Remove distributor cap and rotor. 2. Remove vacuum advance unit and magnetic pickup assembly. 3. Remove attaching screws and lift base plate from distributor. 4. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Vacuum Spark Delay Valve > Component Information > Description and Operation Vacuum Spark Delay Valve: Description and Operation Fig.25 - Spark Delay Valve This unit is used in conjunction with some of the other Ford systems. Its purpose is to further reduce emissions by delaying the spark advance during rapid acceleration and by cutting off advance immediately upon deceleration. Fig. 25. This plastic disc-shaped valve is installed in the carburetor vacuum line at the distributor advance diaphragm. It is a one way valve and will not operate if installed backwards. The black side of the valve must be toward the carburetor. This valve cannot be repaired. NOTE: On all systems which employ the dual diaphragm distributor the line which has high vacuum at idle (normal operating temperature) is connected to the secondary (retard) side of the distributor vacuum advance unit. This is the connection closest to the distributor cap. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Vacuum Spark Delay Valve > Component Information > Description and Operation > Page 1816 Vacuum Spark Delay Valve: Testing and Inspection Fig.36 - SDV Valve Color Coding Fig.37 - Spark Delay Valve (SDV) Specifications Chart Refer to Figs. 36 & 37 for number value by color code. NOTE: To perform the following procedure, an external vacuum source capable of maintaining a minimum constant 10 inches Hg. is required. Mono Delay Valve 1. Set external vacuum source to 10 inches Hg. and connect black side of delay valve to vacuum source. 2. Connect a vacuum gauge with a 24 inch hose to colored side of delay valve. 3. Apply 10 inches Hg. vacuum and observe time in seconds for gauge to read 0-8 inches Hg. The minimum and maximum time for gauge to read 8 inches Hg. should be as shown in Fig. 37. Dual Delay Valve 1. Set external vacuum source to 10 inches Hg. and connect vacuum gauge with a 24 inch hose to DIST nipple of delay valve. 2. Connect black side of delay valve and CARB nipple of delay valve to vacuum source. NOTE: Avoid applying vacuum to CARB nipple while applying vacuum to black side of valve. 3. Apply 10 inches Hg. of vacuum and observe time in seconds for gauge to read from 0-8 inches Hg. The minimum and maximum time for gauge to read 8 inches Hg. should be as shown in Fig. 37. Retard Delay Valve 1. Set external vacuum source to 10 inches Hg. and connect colored side of delay valve to vacuum source. 2. Connect a vacuum gauge with a 24 inch hose to white side of delay valve. 3. Apply 10 inches Hg. of vacuum and observe time in seconds for gauge to read from 0-8 inches Hg. The minimum and maximum time for gauge to read 8 inches Hg. should be as shown in Fig. 37. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams Ignition Cable: Diagrams Spark Plug Wire Routing Ford F 250 5.8L Firing Order Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Page 1820 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Page 1821 Ignition Cable: Testing and Inspection Spark Plug Wire Resistance *** UPDATED BY TSB #85-9-33 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Ignition - Coil Durability/Radio Frequency Interference Ignition Coil: Technical Service Bulletins Ignition - Coil Durability/Radio Frequency Interference Article No. 84-22-8 IGNITION - COIL DURABILITY AND RADIO FREQUENCY INTERFERENCE LIGHT TRUCKS 1985 AND PRIOR YEARS - ALL SERIES MEDIUM/HEAVY TRUCKS 1985 AND PRIOR YEARS - ALL SERIES Relocation of the ignition coil to accomodate the installation of non-Ford engine-mounted equipment may effect the durability of the coil and/or cause a radio frequency interference condition. For these reasons movement of the ignition coil from its original location is not recommended. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Page 1826 Ignition Coil: Specifications Winding Resistance (ohms at 75 degrees F or 24 degrees C) 1981: Primary, 0-1; Secondary, 7700-9600. 1982-88 w/Dura-Spark; Primary, 0.8-1.6; Secondary, 7700-10,500. 1984-88 w/TFI (EEC IV): Primary, 0.3-1.0; Secondary, 8000-11,500. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Page 1827 Ignition Coil: Locations RH Side Of V8-302/5. Applicable to: 5.0L & V8-351/5.8L w/EEC Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Technical Service Bulletins > Page 1828 Ignition Coil: Testing and Inspection 1. Disconnect ignition coil electrical connector. 2. Using a suitable ohmmeter, measure resistance between coil Batt. terminal and Tach terminal. 3. If reading obtained is 0.8---1.6 ohms, coil is satisfactory. If not, replace coil. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Description and Operation Ignition Control Module: Description and Operation Typical Ignition System The Ignition Module shuts off the primary circuit each time it receives a pulse from the magnetic pick-up Fig. 9. A timing circuit in the ignition module turns the primary current back on after a short period of time. High voltage is created each time the magnetic field is built up and collapsed. The red ignition module wire provides operating voltage for the module's electronic components in the Run mode. The white module wire and start bypass provide increased voltage for the module and coil during Start mode. Ignition Modules Dura Spark II systems with UIM (Universal Ignition Module) Fig. 10 can respond to another control signal from either an Ignition Barometric Pressure Switch, Ignition Timing Vacuum Switch, or the Microprocessor Control Unit (MCU), depending on the engine calibration. Responding to this second signal, the UIM provides additional spark timing control for certain operating conditions by shutting off the ignition coil current flow at a different time than with just the distributor pick-up signal. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Description and Operation > Page 1832 Module Identification Chart For proper ignition module identification refer to Fig. 1. The modules are not interchangeable, Dura Spark II has 6 wire connector while Dura Spark III has a 5 wire connector. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing Connector > Component Information > Description and Operation Ignition Timing Connector: Description and Operation Fig. 20 Ignition Timing Vacuum Switch Below vacuum setting, this switch, Fig. 20, used on some vehicles, is open and signals the ignition module to retard spark timing. The switch is closed above the vacuum setting and the ignition module is in the non-retard spark timing mode. Calibration resistors inside the switch control the amount of retard. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing Connector > Component Information > Description and Operation > Page 1836 Ignition Timing Connector: Testing and Inspection Ignition Timing Vacuum Switch Ignition Timing Vacuum Switch Test Chart 1. Disconnect switch from ignition module. 2. Connect suitable ohmmeter across switch terminals and compare resistance measured to ``less than'' values in the Ignition Timing vacuum Switch Test chart. 3. Apply vacuum to switch, using an outside vacuum source. Compare resistance now measured across switch terminals to ``greater than'' values in the Ignition Timing vacuum Switch Test chart. 4. Replace switch if resistance is not within specifications. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Description and Operation Knock Sensor: Description and Operation Knock Sensor The knock sensor, Fig. 11, is a piezo-electric accelerator accelerometer with the sensor designed to resonate at approximately the same frequency as the engine knock frequency.. The sensor uses the resonant frequency to mechanically amplify the engine knock frequency (5-6 KHz). This method allows relatively large signals to be achieved without electrical amplification. The sensor has a thin circular piezoelectric ceramic disk which is bonded to a metal diaphragm. Electrical connections are made through a two-pin integral connector. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Testing and Inspection > Component Testing Knock Sensor: Testing and Inspection Component Testing Fig.8 - MCU System Wiring Circuit 1. Make sure that the following three steps are properly conducted in order to simulate spark knock conditions and determine that spark detection system is inoperative. If not, repeat test to verify problem. a. Make sure that engine is at normal operating temperature. Run engine at 2000 rpm for 2 minutes, then turn key off. Immediately restart engine and allow to idle. b. Observe voltmeter and vacuum gauge for initialization pulses after restarting the engine. The throttle kicker will also extend (increase engine speed) and remain on throughout the test. c. On vehicles with spark knock sensor, when initial pulses occur, immediately simulate spark knock by placing a 3/8 inch extension on manifold near base of knock sensor. Tap end of extension with a small hammer for about 15 seconds. 2. Disconnect jumper wire from self-test trigger input circuit 201. 3. With ignition key off, disconnect vehicle harness from spark knock sensor. 4. Using a torque wrench and a 1 1/8 inch deep socket, make sure that spark sensor is torqued to 12-18 ft. lbs. If sensor is properly torqued, proceed to next step. If not, torque to specifications. 5. Disconnect vehicle harness from MCU and spark sensor. Connect one lead of an ohmmeter to circuit 310 of vehicle harness and other lead to engine block, Fig. 8. If resistance is 1000 ohms or more, proceed to next step. If resistance is less than 1000 ohms, repair short to ground in circuit 301. 6. With key off and knock sensor harness disconnected, check circuit 310 of vehicle harness for continuity. If resistance is 10 ohms or less, continue to next step. If resistance is greater than 10 ohms, repair circuit 310. 7. Check circuit 60 of vehicle harness for continuity between knock sensor and MCU, Fig. 8. If resistance is 10 ohms or less, reconnect harness connector to MCU and proceed to next step. If resistance is greater than 10 ohms, service circuit 60. 8. Reconnect jumper wire to circuits 201 and 60 of VIP connector, Fig. 8. 9. Connect a test lamp to positive terminal of battery, then disconnect knock sensor from vehicle harness. 10. Perform "Engine Running Functional Test" procedure. When the four initialization pulses occur, continuously tap circuit 310 of the vehicle harness connector, which mates to the knock sensor connector, with the probe end for 5 seconds while observing voltmeter pulses. If a code 25 is Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Testing and Inspection > Component Testing > Page 1842 observed, replace MCU. If any other code is observed, replace spark knock sensor. SPARK KNOCK, ONLY AT WIDE OPEN THROTTLE AND/OR POOR PERFORMANCE/MILEAGE 1. If engine has a spark knock sensor, disconnect it. 2. Make sure that ignition timing is within specifications. 3. With engine running at normal operating temperature, disconnect the two wire ignition module connector (yellow wire is circuit 324 and black/white wire is circuit 69) from vehicle harness. Using a jumper wire, jump the wires together at the ignition module and note ignition timing. Remove jumper wire and note ignition timing. If timing retards 16-20 degrees, reconnect ignition module and proceed to next step. If timing does not retard 16-20 degrees, replace ignition module and repeat steps 1, 2 and 3. 4. With engine at normal operating temperature, set high cam on lowest step that will maintain engine speed greater than 1200 rpm. Note ignition timing, then disconnect and plug vacuum hose from zone vacuum switch and again note timing. If timing retards more than 5 degrees, on engines with spark knock sensor, proceed to step 6, on all other engines MCU system is okay. If timing does not retard more than 5 degrees, proceed to next step. 5. With engine still at 1200 rpm, disconnect ignition module (connector with yellow and black/white wires). If timing retards, check circuit 324 for short to ground. If circuit is okay, replace MCU unit and retest. If timing does not retard, check circuit 324 for open circuit. If circuit is okay, Replace MCU unit and retest. 6. On engines with spark knock sensor, reconnect sensor. Repeat Engine Running Functional Test, but do not simulate knock by taping sensor. If service code 25 appears, MCU system is okay, testing is completed. If any other service code appears, replace knock sensor and retest. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Pick-Up Coil, Ignition > Component Information > Specifications > Electrical Specifications DISTRIBUTOR PICKUP Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Pick-Up Coil, Ignition > Component Information > Specifications > Electrical Specifications > Page 1847 DISTRIBUTOR PICKUP Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Pick-Up Coil, Ignition > Component Information > Specifications > Page 1848 Pick-Up Coil: Testing and Inspection Procedure 1. Disconnect distributor electrical connector. Inspect connections for dirt or corrosion. 2. Using a suitable ohmmeter, measure resistance across orange and purple wires in distributor connector. 3. If readings obtained are within 400---1000 ohms, circuit is satisfactory. If readings are less than 400 or more than 1000 ohms, replace stator assembly. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Description and Operation Ignition Control Module: Description and Operation Typical Ignition System The Ignition Module shuts off the primary circuit each time it receives a pulse from the magnetic pick-up Fig. 9. A timing circuit in the ignition module turns the primary current back on after a short period of time. High voltage is created each time the magnetic field is built up and collapsed. The red ignition module wire provides operating voltage for the module's electronic components in the Run mode. The white module wire and start bypass provide increased voltage for the module and coil during Start mode. Ignition Modules Dura Spark II systems with UIM (Universal Ignition Module) Fig. 10 can respond to another control signal from either an Ignition Barometric Pressure Switch, Ignition Timing Vacuum Switch, or the Microprocessor Control Unit (MCU), depending on the engine calibration. Responding to this second signal, the UIM provides additional spark timing control for certain operating conditions by shutting off the ignition coil current flow at a different time than with just the distributor pick-up signal. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Description and Operation > Page 1853 Module Identification Chart For proper ignition module identification refer to Fig. 1. The modules are not interchangeable, Dura Spark II has 6 wire connector while Dura Spark III has a 5 wire connector. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications CRANKSHAFT SENSOR Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 1858 Crankshaft Position Sensor: Locations RH Front Of Engine Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 1859 Crankshaft Position Sensor: Description and Operation Fig.6 - Crankshaft Position Sensor Fig.7 - Crankshaft Position Sensor DESCRIPTION The crankshaft vibration damper is fitted with a four-lobe "pulse ring" which provides the system with an accurate indication of when the pistons reach 10 BTDC. This indication is called the reference timing. Figs. 6 and 7. The pulse ring is a powdered metal ring positioned on the crankshaft vibration damper during manufacture. It has four equally spaced lobes which represent crankshaft position when the pistons reach 10 BTDC. During operation, the lobes on the pulse ring pass by the tip of the CP sensor. The pulse ring interrupts the magnetic field at the tip of the sensor. When the field is interrupted, an output signal is generated and sent to the ECA. As the crankshaft turns, the ECA evaluates the electrical impulses to determine the exact position of the crankshaft at any given time. By the frequency of the impulses, the ECA can determine the engine speed. With these two factors, the ECA will determine the appropriate ignition timing advance required for best engine operation. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Component Information > Service and Repair Ignition Switch: Service and Repair Fig. 3 Ignition switch replacement 1. Disconnect battery ground cable. 2. Remove steering column shroud and lower the steering column. 3. Disconnect electrical connector from switch, then remove 2 switch attaching nuts. 4. Lift switch up to disengage actuator rod, then remove switch from vehicle, Fig. 3. 5. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Description and Operation Knock Sensor: Description and Operation Knock Sensor The knock sensor, Fig. 11, is a piezo-electric accelerator accelerometer with the sensor designed to resonate at approximately the same frequency as the engine knock frequency.. The sensor uses the resonant frequency to mechanically amplify the engine knock frequency (5-6 KHz). This method allows relatively large signals to be achieved without electrical amplification. The sensor has a thin circular piezoelectric ceramic disk which is bonded to a metal diaphragm. Electrical connections are made through a two-pin integral connector. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Testing and Inspection > Component Testing Knock Sensor: Testing and Inspection Component Testing Fig.8 - MCU System Wiring Circuit 1. Make sure that the following three steps are properly conducted in order to simulate spark knock conditions and determine that spark detection system is inoperative. If not, repeat test to verify problem. a. Make sure that engine is at normal operating temperature. Run engine at 2000 rpm for 2 minutes, then turn key off. Immediately restart engine and allow to idle. b. Observe voltmeter and vacuum gauge for initialization pulses after restarting the engine. The throttle kicker will also extend (increase engine speed) and remain on throughout the test. c. On vehicles with spark knock sensor, when initial pulses occur, immediately simulate spark knock by placing a 3/8 inch extension on manifold near base of knock sensor. Tap end of extension with a small hammer for about 15 seconds. 2. Disconnect jumper wire from self-test trigger input circuit 201. 3. With ignition key off, disconnect vehicle harness from spark knock sensor. 4. Using a torque wrench and a 1 1/8 inch deep socket, make sure that spark sensor is torqued to 12-18 ft. lbs. If sensor is properly torqued, proceed to next step. If not, torque to specifications. 5. Disconnect vehicle harness from MCU and spark sensor. Connect one lead of an ohmmeter to circuit 310 of vehicle harness and other lead to engine block, Fig. 8. If resistance is 1000 ohms or more, proceed to next step. If resistance is less than 1000 ohms, repair short to ground in circuit 301. 6. With key off and knock sensor harness disconnected, check circuit 310 of vehicle harness for continuity. If resistance is 10 ohms or less, continue to next step. If resistance is greater than 10 ohms, repair circuit 310. 7. Check circuit 60 of vehicle harness for continuity between knock sensor and MCU, Fig. 8. If resistance is 10 ohms or less, reconnect harness connector to MCU and proceed to next step. If resistance is greater than 10 ohms, service circuit 60. 8. Reconnect jumper wire to circuits 201 and 60 of VIP connector, Fig. 8. 9. Connect a test lamp to positive terminal of battery, then disconnect knock sensor from vehicle harness. 10. Perform "Engine Running Functional Test" procedure. When the four initialization pulses occur, continuously tap circuit 310 of the vehicle harness connector, which mates to the knock sensor connector, with the probe end for 5 seconds while observing voltmeter pulses. If a code 25 is Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Testing and Inspection > Component Testing > Page 1868 observed, replace MCU. If any other code is observed, replace spark knock sensor. SPARK KNOCK, ONLY AT WIDE OPEN THROTTLE AND/OR POOR PERFORMANCE/MILEAGE 1. If engine has a spark knock sensor, disconnect it. 2. Make sure that ignition timing is within specifications. 3. With engine running at normal operating temperature, disconnect the two wire ignition module connector (yellow wire is circuit 324 and black/white wire is circuit 69) from vehicle harness. Using a jumper wire, jump the wires together at the ignition module and note ignition timing. Remove jumper wire and note ignition timing. If timing retards 16-20 degrees, reconnect ignition module and proceed to next step. If timing does not retard 16-20 degrees, replace ignition module and repeat steps 1, 2 and 3. 4. With engine at normal operating temperature, set high cam on lowest step that will maintain engine speed greater than 1200 rpm. Note ignition timing, then disconnect and plug vacuum hose from zone vacuum switch and again note timing. If timing retards more than 5 degrees, on engines with spark knock sensor, proceed to step 6, on all other engines MCU system is okay. If timing does not retard more than 5 degrees, proceed to next step. 5. With engine still at 1200 rpm, disconnect ignition module (connector with yellow and black/white wires). If timing retards, check circuit 324 for short to ground. If circuit is okay, replace MCU unit and retest. If timing does not retard, check circuit 324 for open circuit. If circuit is okay, Replace MCU unit and retest. 6. On engines with spark knock sensor, reconnect sensor. Repeat Engine Running Functional Test, but do not simulate knock by taping sensor. If service code 25 appears, MCU system is okay, testing is completed. If any other service code appears, replace knock sensor and retest. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications Spark Plug: Specifications SPARK PLUGS Gap ...................................................................................................................................................... ............................................................ 0.044 in Torque ...................................................................... ............................................................................................................. 14-20 Nm (10-15 ft-lbs) Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 1872 Spark Plug: Service and Repair REMOVAL - Remove the wire from each spark plug by grasping the molded boot with tool T74P-6666-A or equivalent. Twist the boot until it loosens and then pull it off the spark plug. Do not pull on the wire, as the connection may become damaged. - Any wire damaged must be replaced. Each original spark plug wire is numbered for the cylinder to which it is designated. If wires are not numbered, each wire should be numbered as to the plug from which it was removed. - Clean the area around each spark plug port with compressed air. - Using the proper size spark plug socket remove the spark plugs. INSTALLATION Check the gap on each new spark plug and set to specification. See: Specifications Cylinder Numbering And Distributor Location - Install each spark plug and tighten to 14-20 Nm (10-15 ft-lbs). - Coat the inside of each spark plug boot with silicone dielectric compound. Connect each spark plug wire to the plug from which it was removed. Be sure each wire is fully depressed on each plug and molded boot is firmly in place. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing Vacuum Switch <--> [Thermal Vacuum Valve, Vacuum/Dist. Advance] > Component Information > Description and Operation Ignition Timing Vacuum Switch: Description and Operation This system used on some vehicles, consists of an ambient temperature switch, a three-way vacuum valve, a latching relay and an external inline vacuum bleed. The three-way vacuum valve is used to select the carburetor vacuum source that is supplied to the distributor vacuum advance mechanism. The ambient temperature switch provides the switching circuit to determine which vacuum source will be selected as a function of outside air temperature. The latching relay, activated by temperature switch closing, remains energized regardless of temperature switch position which prevents system cycling due to minor ambient temperature changes. The inline vacuum bleed function is to purge the vacuum line in the CTAV system of any excessive gasoline vapors. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Powertrain Management > Ignition System > Vacuum Restrictor > Component Information > Description and Operation Vacuum Restrictor: Description and Operation Fig.30 - Vacuum Restrictor The orifice type flow restrictor, Fig. 30, is used on some systems to control the flow rate and or timing characteristics to the following systems: a. EGR valve timing (opening and closing). b. Part throttle spark advance. c. Purge system. d. Thermactor system The flow rate through the restrictor is the same in both directions. If blocked, it should be replaced. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Technical Service Bulletins > A/T - AOD New Overdrive Band Anchor Pin Band: Technical Service Bulletins A/T - AOD New Overdrive Band Anchor Pin Article No. TRANSMISSION - AUTOMATIC OVERDRIVE 87-22-13 (AOD) - NEW OVERDRIVE BAND ANCHOR PIN - VEHICLES BUILT BEFORE 09/30/86 FORD: 1980-87 MUSTANG, THUNDERBIRD, FORD LINCOLN-MERCURY: 1980-83 MARK VI 1980-87 COUGAR, MERCURY, CONTINENTAL, LINCOLN TOWN CAR LIGHT TRUCK: 1980-87 E SERIES, F SERIES, BRONCO ISSUE: A new overdrive band anchor pin, with a stepped diameter, is available for service. The old pin may have caused overdrive band wear or anchor pin leakage on vehicles built before 09/30/86. NOTE: AOD transmissions built after 09/30/86 have the new design overdrive band anchor pin. This pin is NOT serviceable on transmissions built after 09/30/86. If replacement is required, a new transmission case must be installed. Figure 10 ACTION: If service is required, use the appropriate Car or Light Truck Shop Manual, Section 17-20, for installation of the new overdrive band anchor pin, Figure 10. PART NUMBER PART NAME CLASS E2AZ-7F295-A Anchor Pin C E0AZ-19554-BA Ford Stud and B Bearing Mount OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Adjustments > C5 Transmission Band: Adjustments C5 Transmission Intermediate Band Intermediate Band Adjustment 1. Clean all the dirt from the band adjusting screw area. Remove and discard the locknut 2. Install a new locknut on the adjustment screw. 3. Tighten the adjusting screw using Band Adjusting Ratchet T71 P-77370-H and Socket T71 P-77370-D or equivalent. Tool T71 P-77370-H or equivalent, is a pre-set torque wrench which will click when the torque on the adjusting screw reaches 13.5 Nm (10 lb-ft). 4. Back off the adjusting screw exactly 4 1/4 turns. 5. Hold the adjusting screw from turning and tighten the locknut to 54 Nm (40 lb-ft). Low/Reverse Band Low Reverse Band Adjustment 1. Clean all the dirt from the band adjusting screw area. Remove and discard the locknut. 2. Install a new locknut on the adjusting screw. 3. Tighten the adjusting screw using Band Adjusting Ratchet T71 P-77370-H and Socket T71 P-77370-D or equivalent. Tool T71 P-77370-H or equivalent, is a pre-set torque wrench which will click when the torque on the adjusting screw reaches 13.5 Nm (10 lb-ft). Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Adjustments > C5 Transmission > Page 1887 4. Back off the adjusting screw exactly 3 turns. 5. Hold the adjusting screw from turning and tighten locknut to 54 Nm (40 lb-ft). Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Adjustments > C5 Transmission > Page 1888 Band: Adjustments C6 Transmission INTERMEDIATE BAND ADJUSTMENT NOTE: When making the intermediate band adjustment, the locknut must be discarded and a new one installed each time the band is adjusted. Refer to service bulletins section for additional information on this procedure. 1. Clean dirt from the band adjusting screw. Remove and discard locknut. 2. Install a new locknut and tighten the adjusting screw to 14 Nm (10 ft lbs). 3. Back the screw off exactly 1.5 turns. 4. Hold the adjusting screw from turning and torque the locknut to 48-61 Nm(35-40 ft lbs). Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 831310 > Jun > 83 > A/T - No 3rd to 4th Gear Upshift or Slipping 4th Gear Clutch: Customer Interest A/T - No 3rd to 4th Gear Upshift or Slipping 4th Gear Article No. 83-13-10 TRANSMISSION - AUTOMATIC - AOD NO 3-4 UPSHIFT OR SLIPPING 4TH GEAR FORD 1980-83 FORD, THUNDERBIRD, LTD LINCOLN-MERCURY 1980-83 MERCURY, COUGAR, LINCOLN, MARK, CONTINENTAL, MARQUIS LIGHT TRUCKS 1981-83 F-SERIES AND E-SERIES Customer concerns of a no 3-4 upshift or a slipping 4th gear can result from causes such as: the direct clutch check ball leaking, miscellaneous leakage or a blocked hydraulic circuit condition, improper torque on the valve body or sticking valves, a leaking governor, the converter damper/hub assembly malfunctioning. Replacement of the direct clutch cylinder piston assembly to alleviate check ball leakage has been effective in most instances. To verify the direct clutch circuit leakage concern, perform the pressure test below as stated previously. Leakage in the direct clutch circuit has been attributed most of the time to a leaking check ball in the direct clutch piston. Replacement of the direct clutch piston will alleviate this condition. However, since other factors can be involved, the following additional checks/verifications are listed to aid you in a complete comprehensive concern diagnosis for customer symptoms of a no 3-4 shift or a slipping 4th gear. NOTE: To alleviate the direct clutch check ball wedging concern in the piston, a star washer replaced the staking operation mid-March, 1983. All current service parts depot stock have the updated direct clutch piston level. Preliminary Checks/Information Verify the following steps have been accomplished: ^ Road test the vehicle to verify the customer complaint. A no 3-4 upshift is characterized by staying in 3rd gear. A slipping 4th gear is characterized by engine cut-loose on the 3-4 upshift and no 4th gear drive capability. ^ Check TV rod and see if bent or sticking. ^ Check TV linkage (could be misadjusted long). Bent, sticking or misadjusted TV linkage will not properly synchronize with the carburetor lever at the time a 3-4 shift should occur. ^ Check control pressure and throttle pressure to identify that they are within specifications. The new 3-4 shift valve (refer to TSB 83-10-11) changes the 3-4 shift pattern. The shift will occur at a higher mph. Direct Clutch Pressure Test The direct clutch pressure test outlined below will diagnose a low pressure condition or leakage in the direct clutch circuit. A difference of 15 psi or more between direct clutch pressure and line pressure (read at the forward clutch pressure tap) will prevent a 3-4 shift. 1. Attach 0-300 psi pressure gages to the forward clutch pressure tap and to the direct clutch pressure tap. Gage accuracy must be capable of distinguishing a 15 psi difference. (If this test is done in conjunction with a control pressure test, pressure gages will be attached to all pressure taps.) Have sufficient flexible hose to read the gages in the vehicle. CAUTION: PRESSURE GAGES AFFECT THE SHIFT QUALITY OF THE TRANSMISSION. CARE SHOULD BE TAKEN NOT TO ACCELERATE OR DECELERATE RAPIDLY. POSSIBLE TRANSMISSION FAILURE COULD RESULT. 2. Drive the vehicle. When pressure is applied to the direct clutch, note the difference between the line pressure read at forward clutch pressure tap and the direct clutch pressure. 3. If the difference in pressures is less than 15 psi, the direct clutch circuit is OK. 4. If the difference is greater than 15 psi, there could be a leak in the direct clutch pressure circuit. (Proceed to the No 3-4 Upshift With Direct Clutch Pressure Greater Than 15 PSI Diagnostic Procedure). If the difference does exceed 15 psi, the gages on line pressure and direct clutch pressure can be switched to confirm that gage calibration difference is not the cause. (Proceed to the No 3-4 Upshift With Direct Clutch Pressure Less Than 15 PSI Diagnostic Procedure or to the Slipping 4th Gear Diagnostic Procedure if applicable). No 3-4 Upshift With Direct Clutch Pressure Greater Than 15 PSI (Indicates Linkage) Diagnostic Procedure NOTE: Direct clutch plates burnt will help to confirm leakage in the direct clutch circuit. Replacing only the plates and not finding the cause could Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 831310 > Jun > 83 > A/T - No 3rd to 4th Gear Upshift or Slipping 4th Gear > Page 1897 result in a repeat service. ^ Check torque on valve body bolts. ^ Check to see if main control gasket is blocking an orifice. ^ Check for nicks or porosity in the case passages (valve body to case mating surface). ^ Check the direct clutch piston check ball for leakage - inspect the piston check ball for freedom of movement. Improper seating of check ball will cause leakage. Leakage can be detected by turning the piston upside down (flat side of piston facing you) allowing the check ball to seat in the piston. Pour a small quantity of solvent over the check ball. If solvent drops past the check ball, replace the piston. ^ Inspect the output shaft feed passages and the cup plug for leakage. Apply 5-10 psi air to the output shaft feed passages. Refer to the AOD operation and diagnosis guide (course 1720-001) p. 32 for location of the feed passages. If air comes out the wrong feed passage, replace the output shaft. ^ Check direct clutch piston seal rings (inner and outer) for leakage. ^ Check all direct clutch output shaft seals for freedom of movement and for metal shavings and burrs between seal and output shaft. ^ Check the direct clutch cylinder for groove marks on the rear ID of the drum. Groove marks indicate the small cast iron seal rings are turning with the output shaft and grooving the cylinder. Groove marks may be caused by contamination or burrs in the output shaft ring groove causing the seal rings to turn with the output shaft. Visually check the output ring grooves carefully. Replace as necessary the output shaft, the seal rings and the cylinder. No 3-4 Upshift With Direct Clutch Pressure Less Than 15 PSI (Indicates No Leakage In The Direct Clutch Circuit) Diagnostic Procedure ^ Clean the valve body. Check for sticking valves as follows: Overdrive servo regulator valve; 3-4 shift valve; 3-4 TV modulator valve; orifice control valve. If any valves are sticking and they cannot be freed, replace valve body. ^ Reduce valve body bolt torque to minimum side of specification 80 in.lbs. ^ Check the fit of the governor counterweight on the output shaft. If the fit is sloppy, replace the counterweight. ^ Check the governor to output shaft retaining ring to make sure it is properly seated on the output shaft. Service as necessary. ^ Check last two large seal rings on the output shaft (#9, #10). They should move freely. Check for metal shaving contamination or burrs between the seal and output shaft. Replace as necessary. ^ Check the seal ring bore at the rear of case for scoring. Light scoring is permissable. Deep grooving indicates case wear. Replace case for deep grooving. Slipping 4th Gear Diagnostic Procedure NOTE: Burnt overdrive band will help confirm leakage in the overdrive circuit. Replacing only the overdrive band without finding the cause will result in a repeat service. If the overdrive band is not burnt, the converter damper/hub weld has usually been found to be suspect. ^ Check overdrive servo cover O-rings and servo piston seal for possible leakage. Replace O-rings and seal if leakage is evident. ^ Verify the overdrive servo cover is not cracked/porous. Coat cover with fluid. Apply air to overdrive servo, apply passage using tool (T80L- 77030-B). Observe to see if air bubbles are present on overdrive servo cover. Replace cover if air bubbles are present. ^ Check the overdrive servo case apply passage to see if it is blocked. Air pressure test. Replace case if necessary. ^ Verify the overdrive servo piston is seated correctly to the band end seat. ^ Verify the overdrive band is seated correctly to anchor pin. ^ Check the torque converter for damper/hub weld failure. Perform converter damper/hub assembly weld check procedure. Refer to Shop Manual, Section 17-01. Use special service tools T83L-7902- A. Replace converter if shaft turns more than two degrees or if there is a grinding noise while applying 50 ft.lbs. torque. ^ Check splines on both ends of the direct driveshaft and in direct clutch cylinder for distortion. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 831310 > Jun > 83 > A/T - No 3rd to 4th Gear Upshift or Slipping 4th Gear Clutch: All Technical Service Bulletins A/T - No 3rd to 4th Gear Upshift or Slipping 4th Gear Article No. 83-13-10 TRANSMISSION - AUTOMATIC - AOD NO 3-4 UPSHIFT OR SLIPPING 4TH GEAR FORD 1980-83 FORD, THUNDERBIRD, LTD LINCOLN-MERCURY 1980-83 MERCURY, COUGAR, LINCOLN, MARK, CONTINENTAL, MARQUIS LIGHT TRUCKS 1981-83 F-SERIES AND E-SERIES Customer concerns of a no 3-4 upshift or a slipping 4th gear can result from causes such as: the direct clutch check ball leaking, miscellaneous leakage or a blocked hydraulic circuit condition, improper torque on the valve body or sticking valves, a leaking governor, the converter damper/hub assembly malfunctioning. Replacement of the direct clutch cylinder piston assembly to alleviate check ball leakage has been effective in most instances. To verify the direct clutch circuit leakage concern, perform the pressure test below as stated previously. Leakage in the direct clutch circuit has been attributed most of the time to a leaking check ball in the direct clutch piston. Replacement of the direct clutch piston will alleviate this condition. However, since other factors can be involved, the following additional checks/verifications are listed to aid you in a complete comprehensive concern diagnosis for customer symptoms of a no 3-4 shift or a slipping 4th gear. NOTE: To alleviate the direct clutch check ball wedging concern in the piston, a star washer replaced the staking operation mid-March, 1983. All current service parts depot stock have the updated direct clutch piston level. Preliminary Checks/Information Verify the following steps have been accomplished: ^ Road test the vehicle to verify the customer complaint. A no 3-4 upshift is characterized by staying in 3rd gear. A slipping 4th gear is characterized by engine cut-loose on the 3-4 upshift and no 4th gear drive capability. ^ Check TV rod and see if bent or sticking. ^ Check TV linkage (could be misadjusted long). Bent, sticking or misadjusted TV linkage will not properly synchronize with the carburetor lever at the time a 3-4 shift should occur. ^ Check control pressure and throttle pressure to identify that they are within specifications. The new 3-4 shift valve (refer to TSB 83-10-11) changes the 3-4 shift pattern. The shift will occur at a higher mph. Direct Clutch Pressure Test The direct clutch pressure test outlined below will diagnose a low pressure condition or leakage in the direct clutch circuit. A difference of 15 psi or more between direct clutch pressure and line pressure (read at the forward clutch pressure tap) will prevent a 3-4 shift. 1. Attach 0-300 psi pressure gages to the forward clutch pressure tap and to the direct clutch pressure tap. Gage accuracy must be capable of distinguishing a 15 psi difference. (If this test is done in conjunction with a control pressure test, pressure gages will be attached to all pressure taps.) Have sufficient flexible hose to read the gages in the vehicle. CAUTION: PRESSURE GAGES AFFECT THE SHIFT QUALITY OF THE TRANSMISSION. CARE SHOULD BE TAKEN NOT TO ACCELERATE OR DECELERATE RAPIDLY. POSSIBLE TRANSMISSION FAILURE COULD RESULT. 2. Drive the vehicle. When pressure is applied to the direct clutch, note the difference between the line pressure read at forward clutch pressure tap and the direct clutch pressure. 3. If the difference in pressures is less than 15 psi, the direct clutch circuit is OK. 4. If the difference is greater than 15 psi, there could be a leak in the direct clutch pressure circuit. (Proceed to the No 3-4 Upshift With Direct Clutch Pressure Greater Than 15 PSI Diagnostic Procedure). If the difference does exceed 15 psi, the gages on line pressure and direct clutch pressure can be switched to confirm that gage calibration difference is not the cause. (Proceed to the No 3-4 Upshift With Direct Clutch Pressure Less Than 15 PSI Diagnostic Procedure or to the Slipping 4th Gear Diagnostic Procedure if applicable). No 3-4 Upshift With Direct Clutch Pressure Greater Than 15 PSI (Indicates Linkage) Diagnostic Procedure NOTE: Direct clutch plates burnt will help to confirm leakage in the direct clutch circuit. Replacing only the plates and not finding the cause could Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 831310 > Jun > 83 > A/T - No 3rd to 4th Gear Upshift or Slipping 4th Gear > Page 1903 result in a repeat service. ^ Check torque on valve body bolts. ^ Check to see if main control gasket is blocking an orifice. ^ Check for nicks or porosity in the case passages (valve body to case mating surface). ^ Check the direct clutch piston check ball for leakage - inspect the piston check ball for freedom of movement. Improper seating of check ball will cause leakage. Leakage can be detected by turning the piston upside down (flat side of piston facing you) allowing the check ball to seat in the piston. Pour a small quantity of solvent over the check ball. If solvent drops past the check ball, replace the piston. ^ Inspect the output shaft feed passages and the cup plug for leakage. Apply 5-10 psi air to the output shaft feed passages. Refer to the AOD operation and diagnosis guide (course 1720-001) p. 32 for location of the feed passages. If air comes out the wrong feed passage, replace the output shaft. ^ Check direct clutch piston seal rings (inner and outer) for leakage. ^ Check all direct clutch output shaft seals for freedom of movement and for metal shavings and burrs between seal and output shaft. ^ Check the direct clutch cylinder for groove marks on the rear ID of the drum. Groove marks indicate the small cast iron seal rings are turning with the output shaft and grooving the cylinder. Groove marks may be caused by contamination or burrs in the output shaft ring groove causing the seal rings to turn with the output shaft. Visually check the output ring grooves carefully. Replace as necessary the output shaft, the seal rings and the cylinder. No 3-4 Upshift With Direct Clutch Pressure Less Than 15 PSI (Indicates No Leakage In The Direct Clutch Circuit) Diagnostic Procedure ^ Clean the valve body. Check for sticking valves as follows: Overdrive servo regulator valve; 3-4 shift valve; 3-4 TV modulator valve; orifice control valve. If any valves are sticking and they cannot be freed, replace valve body. ^ Reduce valve body bolt torque to minimum side of specification 80 in.lbs. ^ Check the fit of the governor counterweight on the output shaft. If the fit is sloppy, replace the counterweight. ^ Check the governor to output shaft retaining ring to make sure it is properly seated on the output shaft. Service as necessary. ^ Check last two large seal rings on the output shaft (#9, #10). They should move freely. Check for metal shaving contamination or burrs between the seal and output shaft. Replace as necessary. ^ Check the seal ring bore at the rear of case for scoring. Light scoring is permissable. Deep grooving indicates case wear. Replace case for deep grooving. Slipping 4th Gear Diagnostic Procedure NOTE: Burnt overdrive band will help confirm leakage in the overdrive circuit. Replacing only the overdrive band without finding the cause will result in a repeat service. If the overdrive band is not burnt, the converter damper/hub weld has usually been found to be suspect. ^ Check overdrive servo cover O-rings and servo piston seal for possible leakage. Replace O-rings and seal if leakage is evident. ^ Verify the overdrive servo cover is not cracked/porous. Coat cover with fluid. Apply air to overdrive servo, apply passage using tool (T80L- 77030-B). Observe to see if air bubbles are present on overdrive servo cover. Replace cover if air bubbles are present. ^ Check the overdrive servo case apply passage to see if it is blocked. Air pressure test. Replace case if necessary. ^ Verify the overdrive servo piston is seated correctly to the band end seat. ^ Verify the overdrive band is seated correctly to anchor pin. ^ Check the torque converter for damper/hub weld failure. Perform converter damper/hub assembly weld check procedure. Refer to Shop Manual, Section 17-01. Use special service tools T83L-7902- A. Replace converter if shaft turns more than two degrees or if there is a grinding noise while applying 50 ft.lbs. torque. ^ Check splines on both ends of the direct driveshaft and in direct clutch cylinder for distortion. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > Customer Interest: > 861117 > Jun > 86 > A/T - Synthetic Fluid Availability Fluid - A/T: Customer Interest A/T - Synthetic Fluid Availability Article No. 86-11-17 TRANSMISSION - AUTOMATIC - NEW SYNTHETIC DEXRON II ALL WEATHER AUTOMATIC TRANSMISSION FLUID FORD 1986 and PRIOR ESCORT, EXP, FORD, LTD, THUNDERBIRD, MUSTANG, TEMPO; 1986 TAURUS LINCOLN-MERCURY 1982-83 LN7; 1986 and PRIOR LYNX, MERCURY, MARQUIS, COUGAR, CAPRI, TOPAZ, LINCOLN, MARK, CONTINENTAL; 1986 SABLE LIGHT TRUCK 1986 and PRIOR E, F SERIES, BRONCO, BRONCO II, RANGER A new synthetic Dexron II automatic transmission fluid specification number ESR-M2C163-A2, part number E6AZ-19582-B is now available. This fluid will maintain a more constant viscosity through a wider range of temperatures. In the event a vehicle will be operated in extremely cold temperatures for an extended period of time, remove all existing fluid from the transmission (using the procedure shown in the applicable 1986 Car or Light Truck Shop Manual) and replace with the new synthetic Dexron II fluid, E6AZ-19582-B. The synthetic fluid is year 'round fluid and will not require replacement for warmer weather. CAUTION: DO NOT use synthetic Dexron II fluid in transmissions designed to use Type "F" fluid. PART NUMBER PART NAME CLASS E6AZ-19582-B Synthetic Dexron Oil V Automatic Transmission Oil OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 06-14-4 > Jul > 06 > A/T Mercon V ATF Usage Fluid - A/T: All Technical Service Bulletins A/T - Mercon V ATF Usage TSB 06-14-4 07/24/06 MERCON ATF IS BEING REPLACED BY MERCON V ATF AS A SERVICE FLUID. FORD: 1980-1997 Crown Victoria 1981-1997 Mustang, Thunderbird 1981-2003 Escort 1986-1993 Festiva 1986-1997 Taurus 1989-1997 Probe 1994-1997 Aspire 1995-2000 Contour 1980-1996 Bronco 1981-2003 F-150 1981-2004 E-Series, F-Super Duty 1983-1996 Ranger 1986-1996 Aerostar 1991-1997 Explorer 1993-2004 F-53 Motorhome Chassis 1995-1998 Windstar 1997-2004 Expedition 2000-2005 Excursion 2001-2007 Escape 1987-2000 F-B-Series 2000-2007 F-650, F-750 LINCOLN: 1980-1997 Town Car 1981-1997 Continental 1993-1997 Mark VIII 1998-2004 Navigator 2002-2003 Blackwood MERCURY: 1980-1997 Grand Marquis 1981-1997 Cougar 1986-1997 Sable 1987-1999 Tracer 1995-2000 Mystique 1999-2002 Cougar 1993-2002 Villager 1997 Mountaineer 2005-2007 Mariner MERKUR: 1985-1989 XR4TI This article supersedes TSB 01-15-7 to update the vehicle application chart. ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid. ACTION Beginning immediately all automatic transmission / transaxle applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will only continue for however long it takes to deplete what remains in inventory. SERVICE PROCEDURE Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 06-14-4 > Jul > 06 > A/T Mercon V ATF Usage > Page 1917 Service automatic transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V For proper fluid application on current and past model vehicles equipped with automatic transmissions I transaxles refer to the fluid usage chart. (Figure 1) CAUTION AUTOMATIC TRANSMISSIONS / TRANSAXLES THAT REQUIRE MERCON® V SHOULD STILL ONLY USE MERCON(R) V OR DUAL USAGE FLUID LABELED MERCON(R) / MERCON(R) V. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 06-14-4 > Jul > 06 > A/T Mercon V ATF Usage > Page 1918 CAUTION MERCON(R) SP, MOTORCRAFT PREMIUM AUTOMATIC TRANSMISSION FLUID AND MOTORCRAFT M5 ATFS ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS RECOMMENDING THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR TRANSMISSION DAMAGE. CAUTION THE FUNCTIONAL CHARACTERISTICS OF FLUIDS FOR CVT TRANSMISSIONS ARE VERY DIFFERENT THAN THOSE OF OTHER AUTOMATIC TRANSMISSION FLUIDS (ATFS). USE OF A FLUID OTHER THAN MOTORCRAFT CONTINUOUSLY VARIABLE CHAIN TYPE TRANSMISSION FLUID OR ONE LABELED AS MEETING MERCON(R) C WILL CAUSE FUNCTIONALITY CONCERNS AND INTERNAL TRANSMISSION DAMAGE. CAUTION DO NOT USE AUTOMATIC TRANSMISSION FLUID SUPPLEMENTS, ADDITIVES, TREATMENTS OR CLEANING AGENTS. Parts Block WARRANTY STATUS: Information Only Disclaimer Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 871814 > Sep > 87 > A/T, M/T New `Mercon' Transmission Fluid Fluid - A/T: All Technical Service Bulletins A/T, M/T - New `Mercon' Transmission Fluid TRANSMISSION - AUTOMATIC/MANUAL - Article No. NEW FLUID AND USAGE CHART 87-18-14 FORD: 1986 And Prior LTD 1988 And Prior ESCORT, TEMPO, MUSTANG, TAURUS, THUNDERBIRD, FORD LINCOLN-MERCURY: 1986 And Prior CAPRI, MARQUIS 1987 And Prior LYNX 1988 And Prior TOPAZ, SABLE, COUGAR, MERCURY, MARK VII, CONTINENTAL, LINCOLN TOWN CAR MERKUR: 1985-88 XR4Ti 1988 SCORPIO LIGHT TRUCK: 1988 And Prior E SERIES, F SERIES, BRONCO, RANGER, BRONCO II, AEROSTAR ISSUE: A new Transmission Fluid, MERCON (Ford Specification "MERCON") (XT-2- QDX, Quart), (XT-2-DDX, 55 Gallon Drum) is available for service. Use of the Motorcraft "MERCON" transmission fluid, where specified, will improve cold weather shift effort and synchronized operation. ACTION: The chart on page 44 of this TSB gives transmission fluid applications for automatic transmissions and certain manual transmissions for Ford, Lincoln-Mercury, and Merkur vehicles. NOTE: The use of MERCON is NOT RECOMMENDED for power steering systems. The manual transmission lubricant for the 1985 Merkur XR4Ti is a semi-synthetic oil. When adding oil to the transmission, use only E5RY-19C547-A (Ford Specification ESD-M2C175-A) or equivalent. PART NUMBER PART NAME CLASS XT-2-QDX MERCON - Quart V Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 871814 > Sep > 87 > A/T, M/T New `Mercon' Transmission Fluid > Page 1923 XT-2-DDX MERCON - 55 Gallon V Drum E5RY-19C547-A Semi-Synthetic Oil B OTHER APPLICABLE ARTICLES: 82-9-9 Supersedes 85-1-15, 85-6-7 WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid - A/T: > 861117 > Jun > 86 > A/T Synthetic Fluid Availability Fluid - A/T: All Technical Service Bulletins A/T - Synthetic Fluid Availability Article No. 86-11-17 TRANSMISSION - AUTOMATIC - NEW SYNTHETIC DEXRON II ALL WEATHER AUTOMATIC TRANSMISSION FLUID FORD 1986 and PRIOR ESCORT, EXP, FORD, LTD, THUNDERBIRD, MUSTANG, TEMPO; 1986 TAURUS LINCOLN-MERCURY 1982-83 LN7; 1986 and PRIOR LYNX, MERCURY, MARQUIS, COUGAR, CAPRI, TOPAZ, LINCOLN, MARK, CONTINENTAL; 1986 SABLE LIGHT TRUCK 1986 and PRIOR E, F SERIES, BRONCO, BRONCO II, RANGER A new synthetic Dexron II automatic transmission fluid specification number ESR-M2C163-A2, part number E6AZ-19582-B is now available. This fluid will maintain a more constant viscosity through a wider range of temperatures. In the event a vehicle will be operated in extremely cold temperatures for an extended period of time, remove all existing fluid from the transmission (using the procedure shown in the applicable 1986 Car or Light Truck Shop Manual) and replace with the new synthetic Dexron II fluid, E6AZ-19582-B. The synthetic fluid is year 'round fluid and will not require replacement for warmer weather. CAUTION: DO NOT use synthetic Dexron II fluid in transmissions designed to use Type "F" fluid. PART NUMBER PART NAME CLASS E6AZ-19582-B Synthetic Dexron Oil V Automatic Transmission Oil OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 06-14-4 > Jul > 06 > A/T - Mercon V ATF Usage Fluid - A/T: All Technical Service Bulletins A/T - Mercon V ATF Usage TSB 06-14-4 07/24/06 MERCON ATF IS BEING REPLACED BY MERCON V ATF AS A SERVICE FLUID. FORD: 1980-1997 Crown Victoria 1981-1997 Mustang, Thunderbird 1981-2003 Escort 1986-1993 Festiva 1986-1997 Taurus 1989-1997 Probe 1994-1997 Aspire 1995-2000 Contour 1980-1996 Bronco 1981-2003 F-150 1981-2004 E-Series, F-Super Duty 1983-1996 Ranger 1986-1996 Aerostar 1991-1997 Explorer 1993-2004 F-53 Motorhome Chassis 1995-1998 Windstar 1997-2004 Expedition 2000-2005 Excursion 2001-2007 Escape 1987-2000 F-B-Series 2000-2007 F-650, F-750 LINCOLN: 1980-1997 Town Car 1981-1997 Continental 1993-1997 Mark VIII 1998-2004 Navigator 2002-2003 Blackwood MERCURY: 1980-1997 Grand Marquis 1981-1997 Cougar 1986-1997 Sable 1987-1999 Tracer 1995-2000 Mystique 1999-2002 Cougar 1993-2002 Villager 1997 Mountaineer 2005-2007 Mariner MERKUR: 1985-1989 XR4TI This article supersedes TSB 01-15-7 to update the vehicle application chart. ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid. ACTION Beginning immediately all automatic transmission / transaxle applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will only continue for however long it takes to deplete what remains in inventory. SERVICE PROCEDURE Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 06-14-4 > Jul > 06 > A/T - Mercon V ATF Usage > Page 1933 Service automatic transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V For proper fluid application on current and past model vehicles equipped with automatic transmissions I transaxles refer to the fluid usage chart. (Figure 1) CAUTION AUTOMATIC TRANSMISSIONS / TRANSAXLES THAT REQUIRE MERCON® V SHOULD STILL ONLY USE MERCON(R) V OR DUAL USAGE FLUID LABELED MERCON(R) / MERCON(R) V. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 06-14-4 > Jul > 06 > A/T - Mercon V ATF Usage > Page 1934 CAUTION MERCON(R) SP, MOTORCRAFT PREMIUM AUTOMATIC TRANSMISSION FLUID AND MOTORCRAFT M5 ATFS ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS RECOMMENDING THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR TRANSMISSION DAMAGE. CAUTION THE FUNCTIONAL CHARACTERISTICS OF FLUIDS FOR CVT TRANSMISSIONS ARE VERY DIFFERENT THAN THOSE OF OTHER AUTOMATIC TRANSMISSION FLUIDS (ATFS). USE OF A FLUID OTHER THAN MOTORCRAFT CONTINUOUSLY VARIABLE CHAIN TYPE TRANSMISSION FLUID OR ONE LABELED AS MEETING MERCON(R) C WILL CAUSE FUNCTIONALITY CONCERNS AND INTERNAL TRANSMISSION DAMAGE. CAUTION DO NOT USE AUTOMATIC TRANSMISSION FLUID SUPPLEMENTS, ADDITIVES, TREATMENTS OR CLEANING AGENTS. Parts Block WARRANTY STATUS: Information Only Disclaimer Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 871814 > Sep > 87 > A/T, M/T New `Mercon' Transmission Fluid Fluid - A/T: All Technical Service Bulletins A/T, M/T - New `Mercon' Transmission Fluid TRANSMISSION - AUTOMATIC/MANUAL - Article No. NEW FLUID AND USAGE CHART 87-18-14 FORD: 1986 And Prior LTD 1988 And Prior ESCORT, TEMPO, MUSTANG, TAURUS, THUNDERBIRD, FORD LINCOLN-MERCURY: 1986 And Prior CAPRI, MARQUIS 1987 And Prior LYNX 1988 And Prior TOPAZ, SABLE, COUGAR, MERCURY, MARK VII, CONTINENTAL, LINCOLN TOWN CAR MERKUR: 1985-88 XR4Ti 1988 SCORPIO LIGHT TRUCK: 1988 And Prior E SERIES, F SERIES, BRONCO, RANGER, BRONCO II, AEROSTAR ISSUE: A new Transmission Fluid, MERCON (Ford Specification "MERCON") (XT-2- QDX, Quart), (XT-2-DDX, 55 Gallon Drum) is available for service. Use of the Motorcraft "MERCON" transmission fluid, where specified, will improve cold weather shift effort and synchronized operation. ACTION: The chart on page 44 of this TSB gives transmission fluid applications for automatic transmissions and certain manual transmissions for Ford, Lincoln-Mercury, and Merkur vehicles. NOTE: The use of MERCON is NOT RECOMMENDED for power steering systems. The manual transmission lubricant for the 1985 Merkur XR4Ti is a semi-synthetic oil. When adding oil to the transmission, use only E5RY-19C547-A (Ford Specification ESD-M2C175-A) or equivalent. PART NUMBER PART NAME CLASS XT-2-QDX MERCON - Quart V Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid - A/T: > 871814 > Sep > 87 > A/T, M/T New `Mercon' Transmission Fluid > Page 1939 XT-2-DDX MERCON - 55 Gallon V Drum E5RY-19C547-A Semi-Synthetic Oil B OTHER APPLICABLE ARTICLES: 82-9-9 Supersedes 85-1-15, 85-6-7 WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Refill Capacity Fluid - A/T: Specifications Type MERCON(R) Automatic Transmission Fluid CAPACITY, Initial Refill*: C-6 5.0 qt (US) With the engine at operating temperature, shift transmission through all gears. Check fluid level in PARK and add fluid as needed Others 3.0 qt (US) Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Refill Capacity > Page 1942 Fluid - A/T: Specifications Type MA(MERCON (R) Automatic Transmission Fluid) CAPACITY, Total Fill: Tempo, Topaz 8.3 qt (US) Others 9.8 qt (US) Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 85247 > Dec > 85 > A/T - AOD Fluid Leak Fluid Pump: Customer Interest A/T - AOD Fluid Leak Article No. 85-24-7 LEAK - TRANSMISSION FLUID (AOD) - FRONT PUMP SEAL FORD 1980-85 FORD, THUNDERBIRD, LTD, MUSTANG LINCOLN-MERCURY 1980-85 MERCURY, COUGAR, MARQUIS, CAPRI, LINCOLN, MARK, CONTINENTAL LIGHT TRUCK 1982-85 E AND F SERIES, BRONCO Figure 12 - Front Pump Seal Transmission fluid leaks at the front pump seal in vehicles equipped with an AOD transmission built prior to October 1, 1985 may be caused by a variation in location of the fluid drainback hole at the pump allowing fluid to leak around the seal. If the drainback hole bridges across the outer edge of the pump seal, the seal may collapse in the hole causing a leak past the outside diameter of the seal (Figure 12). 1. Remove the front pump seal using procedures outlined in Section l7-20-34 of the 1985 Car Shop Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 85247 > Dec > 85 > A/T - AOD Fluid Leak > Page 1951 Manual, Volume D. 2. Check the relationship of the drainback hole at the pump body to the sealing face of the seal (Figure 12). If the hole bridges the seal metal face, thoroughly clean and dry the pump body seal mating surface with spot remover (B7A-19521-A). Figure 14 - Front Pump Seal - Outside Diameter Metal Surface 3. Obtain a new seal (C2AZ-7A248-A) and clean any oil that may be on the metal surface. Apply silicone sealant (E3AZ-19562-A) in a continuous 1/16" to 1/8" diameter bead to the outside diameter metal surface of the seal (Figure 14, Step 1). Distribute the bead of sealant into a thin film as shown. NOTE: The silicone sealant is distributed in a cartridge tube. The nozzle should be cut to permit a flow of sealant 1/16" to 1/8" in diameter. Do not apply more than a 1/8" bead as the drainback hole could become plugged. 4. Apply a 1/16" to 1/8" diameter bead of sealant in the corner of the pocket of the pump body seal mating surface (Figure 14, Step 2). NOTE: The bead must be adequate across the drainback hole but not plug the hole. If the hole is blocked, drainback behind the seal will not be provided and leakage could still occur. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > Customer Interest for Fluid Pump: > 85247 > Dec > 85 > A/T - AOD Fluid Leak > Page 1952 5. Push seal in place and smear the excess sealant as shown in Figure 14, Step 3. Figure 13 - Front Pump Seal/Revised Hole Location Transmissions built after October 1, 1985 are equipped with a front pump that has a revised drainback hole located away from the seal edge mating surface (Figure 13). Depot stock has been replaced with pumps having the revised location drainback hole. PART NUMBER PART NAME CLASS B7A-19521-A Spot Remover A C2AZ-7A248-A Pump Seal A E3AZ-19562-A Silicone Sealant A OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP7248A85 TIME: 3.4 Hrs. - Mustang/Capri, LTD/Marquis, Thunderbird/Cougar, Mark VII/Continental 2.8 Hrs. - Ford, Mercury, Lincoln 3.0 Hrs. - 4x2 F Series 4.9L/5.0L 2.7 Hrs. - 4x2 Econoline 4.9L/5.0L 4.3 Hrs. - 4x4 F Series and Bronco 5.0L OPERATION: SP7248B85 - Supplement extra time if equipped with skid plate under the transfer case TIME: 0.2 Hr. DLR. CODING: Basic Part No. 7A248 - Code: 77 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 85247 > Dec > 85 > A/T - AOD Fluid Leak Fluid Pump: All Technical Service Bulletins A/T - AOD Fluid Leak Article No. 85-24-7 LEAK - TRANSMISSION FLUID (AOD) - FRONT PUMP SEAL FORD 1980-85 FORD, THUNDERBIRD, LTD, MUSTANG LINCOLN-MERCURY 1980-85 MERCURY, COUGAR, MARQUIS, CAPRI, LINCOLN, MARK, CONTINENTAL LIGHT TRUCK 1982-85 E AND F SERIES, BRONCO Figure 12 - Front Pump Seal Transmission fluid leaks at the front pump seal in vehicles equipped with an AOD transmission built prior to October 1, 1985 may be caused by a variation in location of the fluid drainback hole at the pump allowing fluid to leak around the seal. If the drainback hole bridges across the outer edge of the pump seal, the seal may collapse in the hole causing a leak past the outside diameter of the seal (Figure 12). 1. Remove the front pump seal using procedures outlined in Section l7-20-34 of the 1985 Car Shop Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 85247 > Dec > 85 > A/T - AOD Fluid Leak > Page 1958 Manual, Volume D. 2. Check the relationship of the drainback hole at the pump body to the sealing face of the seal (Figure 12). If the hole bridges the seal metal face, thoroughly clean and dry the pump body seal mating surface with spot remover (B7A-19521-A). Figure 14 - Front Pump Seal - Outside Diameter Metal Surface 3. Obtain a new seal (C2AZ-7A248-A) and clean any oil that may be on the metal surface. Apply silicone sealant (E3AZ-19562-A) in a continuous 1/16" to 1/8" diameter bead to the outside diameter metal surface of the seal (Figure 14, Step 1). Distribute the bead of sealant into a thin film as shown. NOTE: The silicone sealant is distributed in a cartridge tube. The nozzle should be cut to permit a flow of sealant 1/16" to 1/8" in diameter. Do not apply more than a 1/8" bead as the drainback hole could become plugged. 4. Apply a 1/16" to 1/8" diameter bead of sealant in the corner of the pocket of the pump body seal mating surface (Figure 14, Step 2). NOTE: The bead must be adequate across the drainback hole but not plug the hole. If the hole is blocked, drainback behind the seal will not be provided and leakage could still occur. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 85247 > Dec > 85 > A/T - AOD Fluid Leak > Page 1959 5. Push seal in place and smear the excess sealant as shown in Figure 14, Step 3. Figure 13 - Front Pump Seal/Revised Hole Location Transmissions built after October 1, 1985 are equipped with a front pump that has a revised drainback hole located away from the seal edge mating surface (Figure 13). Depot stock has been replaced with pumps having the revised location drainback hole. PART NUMBER PART NAME CLASS B7A-19521-A Spot Remover A C2AZ-7A248-A Pump Seal A E3AZ-19562-A Silicone Sealant A OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP7248A85 TIME: 3.4 Hrs. - Mustang/Capri, LTD/Marquis, Thunderbird/Cougar, Mark VII/Continental 2.8 Hrs. - Ford, Mercury, Lincoln 3.0 Hrs. - 4x2 F Series 4.9L/5.0L 2.7 Hrs. - 4x2 Econoline 4.9L/5.0L 4.3 Hrs. - 4x4 F Series and Bronco 5.0L OPERATION: SP7248B85 - Supplement extra time if equipped with skid plate under the transfer case TIME: 0.2 Hr. DLR. CODING: Basic Part No. 7A248 - Code: 77 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > A/T - AOD Main Control Valve Body Gasket Seals and Gaskets: Technical Service Bulletins A/T - AOD Main Control Valve Body Gasket Article No. 86-13-17 TRANSMISSION - AUTOMATIC - AOD - MAIN CONTROL VALVE BODY GASKETS FORD 1980-86 FORD, THUNDERBIRD, LTD, MUSTANG LINCOLN-MERCURY 1980-83 MARK VI; 1980-86 MERCURY, COUGAR, MARQUIS, CAPRI, LINCOLN, CONTINENTAL; 1984-86 MARK VII LIGHT TRUCK 1981-86 E SERIES, F SERIES, BRONCO Figure 11 Figure 12 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > A/T - AOD Main Control Valve Body Gasket > Page 1964 New upper and lower main control valve body gaskets have been released for service. The new gasket has an additional slot, which reduces the chance for contamination of the 3-4 shift valve (refer to Figures 11 and 12). The new gaskets can be used on all AOD main control valve bodies produced for the 1980-86 model years. Old upper and lower main control valve body gaskets (EOAZ-7D100-B and EOAZ-7C155-A) may still be used on certain applications. To identify the correct application, the middle letter of the main control valve body's three-letter I.D. code is necessary. Refer to the following service usage chart for the correct gasket applications. SERVICE USAGE CHART FOR AOD MAIN CONTROL VALVE BODY GASKETS AOD Valve Body Old Gaskets New Gaskets I.D. Codes EOAZ-7D100-B E6AZ-7D100-A (Middle Letter) EOAZ-7C155-A E6AZ-7C155-A A, B, C, D, E Acceptable Acceptable T, U, V, W, X, Y, Z All other than above Must NOT Use Must Use (For example: main controls with middle letter I.D. code F, G, H, . . . Q, R, S) OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Component Information > Technical Service Bulletins > Recalls for Shift Linkage: > NHTSA82V004000 > Jan > 82 > Recall 82V004000: Shift Rod Attachment Shift Linkage: Recalls Recall 82V004000: Shift Rod Attachment ON SOME OF THE INVOLVED VEHICLES, THE SHIFT ROD IN THE TRANSMISSION MAY NOT BE PROPERLY SEATED IN THE RETENTION GROMMET OF THE STEERING COLUMN SHIFT LEVER ASSEMBLY. IF THE SHIFT ROD WERE TO DISENGAGE, THE DRIVER COULD NOT SELECT THE PROPER TRANSMISSION FUNCTION WHICH WOULD CREATE THE POTENTIAL FOR UNEXPECTED MOVEMENT OF THE VEHICLE. DEALER WILL INSPECT THE SHIFT ROD ATTACHMENT AND MAKE SURE IT IS PROPERLY SEATED AT NO COST TO OWNER. VEHICLE DESCRIPTION: TRUCKS EQUIPPED WITH AUTOMATIC TRANSMISSIONS. SYSTEM: POWER TRAIN; TRANSMISSION SHIFT LINKAGE. CONSEQUENCES OF DEFECT: SHOULD SEPARATION OCCUR WHILE VEHICLE IS IN OPERATION, LOSS OF VEHICLE CONTROL, AN ACCIDENT, AND PERSONAL INJURY COULD OCCUR. NOTE: THE DRIVER IS ADVISED NOT TO OPERATE VEHICLE UNTIL PROPER ADJUSTMENTS HAVE BEEN MADE. 1982 FORD TRUCK CLUB WAGON 1982 FORD TRUCK E100 1982 FORD TRUCK E150 1982 FORD TRUCK E250 1982 FORD TRUCK E350 1982 FORD TRUCK ECONOLINE Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Linkage: > NHTSA82V004000 > Jan > 82 > Recall 82V004000: Shift Rod Attachment Shift Linkage: All Technical Service Bulletins Recall 82V004000: Shift Rod Attachment ON SOME OF THE INVOLVED VEHICLES, THE SHIFT ROD IN THE TRANSMISSION MAY NOT BE PROPERLY SEATED IN THE RETENTION GROMMET OF THE STEERING COLUMN SHIFT LEVER ASSEMBLY. IF THE SHIFT ROD WERE TO DISENGAGE, THE DRIVER COULD NOT SELECT THE PROPER TRANSMISSION FUNCTION WHICH WOULD CREATE THE POTENTIAL FOR UNEXPECTED MOVEMENT OF THE VEHICLE. DEALER WILL INSPECT THE SHIFT ROD ATTACHMENT AND MAKE SURE IT IS PROPERLY SEATED AT NO COST TO OWNER. VEHICLE DESCRIPTION: TRUCKS EQUIPPED WITH AUTOMATIC TRANSMISSIONS. SYSTEM: POWER TRAIN; TRANSMISSION SHIFT LINKAGE. CONSEQUENCES OF DEFECT: SHOULD SEPARATION OCCUR WHILE VEHICLE IS IN OPERATION, LOSS OF VEHICLE CONTROL, AN ACCIDENT, AND PERSONAL INJURY COULD OCCUR. NOTE: THE DRIVER IS ADVISED NOT TO OPERATE VEHICLE UNTIL PROPER ADJUSTMENTS HAVE BEEN MADE. 1982 FORD TRUCK CLUB WAGON 1982 FORD TRUCK E100 1982 FORD TRUCK E150 1982 FORD TRUCK E250 1982 FORD TRUCK E350 1982 FORD TRUCK ECONOLINE Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Cooler: > 842014 > Sep > 84 > A/T - Oil Cooler Overheating During Cold Weather Transmission Cooler: Customer Interest A/T - Oil Cooler Overheating During Cold Weather Article No. 84-20-14 TRANSMISSION - AUTOMATIC - EXTERNAL TRANSMISSION OIL COOLER OVERHEATING DURING OPERATION IN EXTREMELY COLD WEATHER (-30~F/-34~C) ALL E & F-SERIES EXCEPT F250/ 350 WITH 6.9L DIESEL ENGINE LIGHT TRUCKS 1982-84 E & F SERIES Automatic transmission overheating reported on referenced model vehicles operating in low ambient temperatures of minus 30~F/minus 34~C or below may be the result of reduced fluid flow through the external oil cooler due to excessive fluid cooling (thickening). This reduced fluid flow may cause loss of fluid or tranmission overheating. Symptoms, after low ambient temperatures operation, are as follows: 1. Change in color of transmission fluid. 2. Smell of fluid or evidence of transmission fluid on or under the vehicle. If the above conditions are noted or if transmission service or replacement is required due to transmission overheating, the external transmission oil cooler (7A095) must be replaced as shown: PARTS AFFECTED VEHICLE USAGE ADD DELETE PART NAME E100-350 E5UZ-7A095-B (24 Plate) E3UH-7A095-BA Aux. Trans. Oil Cooler Assy. E250-350 E5UZ-7A095-A (48 Plate) E3UH-7A095-AB Aux. Trans. Oil Cooler Assy. F100-350 E5TZ-7A095-C (24 Plate) E2TH-7A095-AA Aux. Trans. Oil Cooler Assy. F250-350 E5TZ-7A095-B (48 Plate) E3TH-7A095-AA Aux. Trans. Oil Cooler Assy. The new auxiliary transmission oil cooler assembly (7A095) contains an internal bypass which allows a portion of the transmission fluid to flow more easily through the cooler in extreme cold weather operations. The new oil cooler continues to provide adequate function during vehicle operations under normal or warm weather conditions. The external oil cooler assembly removal and installation procedures for the subject vehicles are as follows: Removal and Installation: 1. Loosen the two tube compression nuts attaching the two steel tubes to the oil cooler assembly (7A095) and remove both tubes from the cooler assembly. Remove the oil cooler assembly (a slight loss of transmission fluid will occur when tubes are disconnected). 2. Install the new cooler assembly to the radiator support. Reconnect the two steel tubes to the cooler assembly. Securely tighten each tube compression nut to assure a leak-proof connection. 3. Check level of transmission fluid in transmission; add fluid to proper level. PART NUMBER PART NAME CLASS E5UZ-7A095-B Aux. Trans. Oil Cooler Assy. R E5UZ-7A095-A Aux. Trans. Oil Cooler Assy. C E5TZ-7A095-C Aux. Trans. Oil Cooler Assy. R E5TZ-7A095-B Aux. Trans. Oil Cooler Assy. C OTHER APPLICABLE ARTICLES: 84-5-19 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP7095B84 TIME: 0.5 Hr. - E-Series 0.4 Hr. - F-Series DLR. CODING: Basic Part No. 7A095 Code: 55 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Cooler: > 842014 > Sep > 84 > A/T - Oil Cooler Overheating During Cold Weather Transmission Cooler: All Technical Service Bulletins A/T - Oil Cooler Overheating During Cold Weather Article No. 84-20-14 TRANSMISSION - AUTOMATIC - EXTERNAL TRANSMISSION OIL COOLER OVERHEATING DURING OPERATION IN EXTREMELY COLD WEATHER (-30~F/-34~C) ALL E & F-SERIES EXCEPT F250/ 350 WITH 6.9L DIESEL ENGINE LIGHT TRUCKS 1982-84 E & F SERIES Automatic transmission overheating reported on referenced model vehicles operating in low ambient temperatures of minus 30~F/minus 34~C or below may be the result of reduced fluid flow through the external oil cooler due to excessive fluid cooling (thickening). This reduced fluid flow may cause loss of fluid or tranmission overheating. Symptoms, after low ambient temperatures operation, are as follows: 1. Change in color of transmission fluid. 2. Smell of fluid or evidence of transmission fluid on or under the vehicle. If the above conditions are noted or if transmission service or replacement is required due to transmission overheating, the external transmission oil cooler (7A095) must be replaced as shown: PARTS AFFECTED VEHICLE USAGE ADD DELETE PART NAME E100-350 E5UZ-7A095-B (24 Plate) E3UH-7A095-BA Aux. Trans. Oil Cooler Assy. E250-350 E5UZ-7A095-A (48 Plate) E3UH-7A095-AB Aux. Trans. Oil Cooler Assy. F100-350 E5TZ-7A095-C (24 Plate) E2TH-7A095-AA Aux. Trans. Oil Cooler Assy. F250-350 E5TZ-7A095-B (48 Plate) E3TH-7A095-AA Aux. Trans. Oil Cooler Assy. The new auxiliary transmission oil cooler assembly (7A095) contains an internal bypass which allows a portion of the transmission fluid to flow more easily through the cooler in extreme cold weather operations. The new oil cooler continues to provide adequate function during vehicle operations under normal or warm weather conditions. The external oil cooler assembly removal and installation procedures for the subject vehicles are as follows: Removal and Installation: 1. Loosen the two tube compression nuts attaching the two steel tubes to the oil cooler assembly (7A095) and remove both tubes from the cooler assembly. Remove the oil cooler assembly (a slight loss of transmission fluid will occur when tubes are disconnected). 2. Install the new cooler assembly to the radiator support. Reconnect the two steel tubes to the cooler assembly. Securely tighten each tube compression nut to assure a leak-proof connection. 3. Check level of transmission fluid in transmission; add fluid to proper level. PART NUMBER PART NAME CLASS E5UZ-7A095-B Aux. Trans. Oil Cooler Assy. R E5UZ-7A095-A Aux. Trans. Oil Cooler Assy. C E5TZ-7A095-C Aux. Trans. Oil Cooler Assy. R E5TZ-7A095-B Aux. Trans. Oil Cooler Assy. C OTHER APPLICABLE ARTICLES: 84-5-19 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP7095B84 TIME: 0.5 Hr. - E-Series 0.4 Hr. - F-Series DLR. CODING: Basic Part No. 7A095 Code: 55 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > A/T - AOD Separator Plate Gasket Changes Valve Body: Technical Service Bulletins A/T - AOD Separator Plate Gasket Changes TRANSMISSION - AOD - MAIN CONTROL GASKET CHANGES AFFECTING USAGE OF SERVICE KITS Article No. 89-23-7 FORD: 1980-90 CROWN VICTORIA 1980-86 LTD 1980-90 THUNDERBIRD 1985-90 MUSTANG LINCOLN-MERCURY: 1980-87 CONTINENTAL 1980-90 COUGAR, GRAND MARQUIS 1980-83 MARK VI 1980-90 TOWN CAR 1984-90 MARK VII 1985 CAPRI, MARQUIS LIGHT TRUCK: 1981-90 BRONCO, ECONOLINE, F-150, F-250 ISSUE: The separator plate lower gasket from the current gasket service kit (7153) and overhaul service kit (7C391) cannot be used on any 1990 model vehicles. ACTION: When servicing 1990 AOD transmissions the separator plate lower gasket found in the current kits must be thrown away and replaced with a new gasket (F0AZ-7D100-A). This new gasket can only be used on 1990 vehicles. CAUTION: USE OF THE SEPARATOR PLATE LOWER GASKET CONTAINED IN THE CURRENT KITS ON 1990 VEHICLES COULD CAUSE A REDUCTION IN THROTTLE VALVE PRESSURE. THIS CAN RESULT IN POSSIBLE TRANSMISSION FAILURES. In the near future, gasket and overhaul kits will no longer contain any main control gaskets. Two main control lower separator plate gasket items will be available. Refer to the following gasket application chart for correct service part usage. PART NUMBER PART NAME CLASS E9AZ-7D100-B Main Control Gasket Kit B FOAZ-7D100-A Separator Plate Lower Gasket B E9SZ-7C155-A Main Control Upper Separator B Plate Gasket OTHER APPLICABLE ARTICLES: none SUPERSEDES: 88-13-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 5100, 5101, 5102, 5200, 5300, 5500, 5800 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > A/T - AOD Separator Plate Gasket Changes > Page 1995 Valve Body: Technical Service Bulletins A/T - AOD Main Control Valve Body Gasket Article No. 86-13-17 TRANSMISSION - AUTOMATIC - AOD - MAIN CONTROL VALVE BODY GASKETS FORD 1980-86 FORD, THUNDERBIRD, LTD, MUSTANG LINCOLN-MERCURY 1980-83 MARK VI; 1980-86 MERCURY, COUGAR, MARQUIS, CAPRI, LINCOLN, CONTINENTAL; 1984-86 MARK VII LIGHT TRUCK 1981-86 E SERIES, F SERIES, BRONCO Figure 11 Figure 12 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > A/T - AOD Separator Plate Gasket Changes > Page 1996 New upper and lower main control valve body gaskets have been released for service. The new gasket has an additional slot, which reduces the chance for contamination of the 3-4 shift valve (refer to Figures 11 and 12). The new gaskets can be used on all AOD main control valve bodies produced for the 1980-86 model years. Old upper and lower main control valve body gaskets (EOAZ-7D100-B and EOAZ-7C155-A) may still be used on certain applications. To identify the correct application, the middle letter of the main control valve body's three-letter I.D. code is necessary. Refer to the following service usage chart for the correct gasket applications. SERVICE USAGE CHART FOR AOD MAIN CONTROL VALVE BODY GASKETS AOD Valve Body Old Gaskets New Gaskets I.D. Codes EOAZ-7D100-B E6AZ-7D100-A (Middle Letter) EOAZ-7C155-A E6AZ-7C155-A A, B, C, D, E Acceptable Acceptable T, U, V, W, X, Y, Z All other than above Must NOT Use Must Use (For example: main controls with middle letter I.D. code F, G, H, . . . Q, R, S) OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > A/T - AOD Separator Plate Gasket Changes > Page 1997 Valve Body: Technical Service Bulletins A/T - AOD Orifice Control Valve Plug Retainer Article No. 85-14-7 TRANSMISSION - AUTOMATIC - AOD - ORIFICE CONTROL VALVE PLUG RETAINER CHANGE FORD 1980-85 FORD, THUNDERBIRD, LTD, MUSTANG LINCOLN-MERCURY 1980-85 MERCURY, COUGAR, MARQUIS, CAPRI, LINCOLN, MARK, CONTINENTAL LIGHT TRUCK 1981-85 E & F SERIES - BRONCO An improved plug retainer design is available for the orifice control valve bore plug in the AOD main control valve body assembly. A retainer plate (E5AZ-7E335-A) replaces the hairpin clip. NOTE: Whenever the AOD main control valve body is disassembled for service, replace the hairpin clip with the retainer plate. For location of the orifice control valve bore, refer to the AOD main control assembly/disassembly section of the Car or Truck Shop Manual. PART NUMBER PART NAME CLASS E5AZ-7E335-A Retainer Plate R OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information > Adjustments Clutch Pedal Assembly: Adjustments NOTE: Clutch pedal total travel is not adjustable on these models. 1. Check clutch pedal free travel by measuring distance from clutch pedal pad to steering wheel rim, then depress clutch pedal until free travel is diminished and take a second measurement. If the difference between the two measurements is less than 1/2 inch, the clutch linkage must be adjusted. 2. Loosen and back off the two jam nuts several turns, then adjust the first jam nut until a free travel measurement of 1 and 1/2 inches is obtained at the clutch pedal. 3. While holding the second jam nut, tighten the first jam nut against the second one. 4. Recheck free pedal travel and readjust as necessary. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Position Switch <--> [Clutch Switch] > Component Information > Testing and Inspection Clutch Pedal Position Switch: Testing and Inspection Manual Transmission Vehicles Only This switch functions magnetically. Do not use magnetized tools near this switch. 1. If the switch is open when the clutch pedal is released, speed control will not operate. This must be corrected before making any other tests. Use only a multimeter of 5000 ohm/volt rating or higher when performing the clutch switch test. 2. Disconnect switch pigtail connector from speed control harness connector and connect an ohmmeter to the two switch connector terminals. 3. With clutch pedal in the fully released position, the resistance should be less than 5 ohms. With clutch pedal fully depressed, the circuit should be open. 4. If switch does not function as described, remove and replace switch. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Bearing, M/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch Release Bearing: > 85214 > Jan > 85 > Clutch Release Bearing Squeak/Scrape Clutch Release Bearing: Customer Interest Clutch - Release Bearing Squeak/Scrape Article No. 85-2-14 CLUTCH - RELEASE BEARING SQUEAK/SCRAPE LIGHT TRUCKS 1982-83 E & F150-350, BRONCO The concern is usually characterized by a squeal which occurs with the engine running and light pressure applied to the clutch pedal. The squeal stops when greater force is applied to the pedal, which occurs when disengaging the clutch. Under light pedal pressure, the release bearing load is insufficient to overcome the friction of the stationary bearing, and metal to metal squeal/scrape results between the bearing and the rotating pressure plate. Under greater axial loads, the bearing rotates with the pressure plate, and the squeal stops. Major factors which tend to increase the tendency for a release bearing to squeal are as follows: 1. Insufficient free play. 2. Lack of clutch housing concentricity and parallelism. 3. Out of plane pressure fingers. The recommended respective diagnostic/service procedure for the above factors are as follows: 1. Check clutch linkage free play per Section 16-03 of 1983 Light Truck Shop Manual. 2. Check clutch housing bore and face run out per Shop Manual procedure Section 16-01. 3. Check pressure plate finger heights per Shop Manual procedure Section 16-01. Replace bearing if all of the above have been investigated and found acceptable. Customers also should be advised that light pedal pressure may result in squeal at the onset of clutch engagement with the free play type clutch linkage system. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP7003D83 TIME: 0.8 Hr. (Plus applicable standard times) DLR. CODING: Basic Part No. 7580 Code: 56 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Bearing, M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Release Bearing: > 85214 > Jan > 85 > Clutch - Release Bearing Squeak/Scrape Clutch Release Bearing: All Technical Service Bulletins Clutch - Release Bearing Squeak/Scrape Article No. 85-2-14 CLUTCH - RELEASE BEARING SQUEAK/SCRAPE LIGHT TRUCKS 1982-83 E & F150-350, BRONCO The concern is usually characterized by a squeal which occurs with the engine running and light pressure applied to the clutch pedal. The squeal stops when greater force is applied to the pedal, which occurs when disengaging the clutch. Under light pedal pressure, the release bearing load is insufficient to overcome the friction of the stationary bearing, and metal to metal squeal/scrape results between the bearing and the rotating pressure plate. Under greater axial loads, the bearing rotates with the pressure plate, and the squeal stops. Major factors which tend to increase the tendency for a release bearing to squeal are as follows: 1. Insufficient free play. 2. Lack of clutch housing concentricity and parallelism. 3. Out of plane pressure fingers. The recommended respective diagnostic/service procedure for the above factors are as follows: 1. Check clutch linkage free play per Section 16-03 of 1983 Light Truck Shop Manual. 2. Check clutch housing bore and face run out per Shop Manual procedure Section 16-01. 3. Check pressure plate finger heights per Shop Manual procedure Section 16-01. Replace bearing if all of the above have been investigated and found acceptable. Customers also should be advised that light pedal pressure may result in squeal at the onset of clutch engagement with the free play type clutch linkage system. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP7003D83 TIME: 0.8 Hr. (Plus applicable standard times) DLR. CODING: Basic Part No. 7580 Code: 56 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Testing and Inspection > Bearing Cups Carrier Bearings: Testing and Inspection Bearing Cups Check bearing cups for rings, spalling, galling or erratic wear patterns. The bearing cups must be solidly seated. Check by attempting to insert .0015 inch feeler gauge between cups and bottoms of bores. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Testing and Inspection > Bearing Cups > Page 2024 Carrier Bearings: Testing and Inspection Cone & Roller Assemblies When operated in the cups, the cone and roller assemblies must turn without any roughness. Examine roller ends for wear. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings > Component Information > Testing and Inspection > Bearing Cups > Page 2025 Carrier Bearings: Testing and Inspection Differential Bearing Adjusters Test fit of bearing adjusters in their threads with bearing caps installed. Ensure that bearing caps are on sides that they were machined to fit. The faces of the adjusters that contact the bearing cups must be smooth and square. Examine threads in carrier if their fit is not proper and replace any adjuster with a damaged face or threads. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Side Gears > Component Information > Testing and Inspection Carrier Side Gears: Testing and Inspection Examine drive pinion and ring gear teeth for scoring or signs of excessive wear. Worn gears cannot be rebuilt to correct a noisy condition. Gear scoring and flaking are the result of excessive shock loading or the use of improper lubricant. Scored gears cannot be reused. Examine teeth and thrust surfaces of differential gears. Wear on hub of differential side gears may cause a chucking noise known as chuckle, when the vehicle is operated at low speeds. Wear of splines, thrust surfaces or thrust washers may contribute to excessive drive line backlash. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Testing and Inspection Differential Case: Testing and Inspection Ensure that hubs where bearings mount are smooth. Check fit of differential gears in the counterbores. Carefully examine thrust washers, which may be damaged when bearings are removed. If differential bearing assemblies do not seat firmly on hubs, failure is certain. Ensure that mating surfaces of the two parts of case and the face of the ring gear attaching flange are smooth and free from nicks and burrs. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Testing and Inspection > Page 2032 Differential Case: Adjustments 1. Attach ring gear to the differential case using new bolts. Torque bolts alternately and evenly to 50---60 ft. lbs. on except model 60 monobeam axle or 100-120 ft. lbs on model 60 monobeam axle. 2. Clean trunnions on the differential and install the master differential bearings on to differential case. Remove all burrs and nicks from hubs so master bearings rotate freely. 3. Place differential case into carrier (without pinion). The differential case should move freely in the carrier assembly. Position a suitable dial indicator against differential case flanges. Locate tip of the indicator on the flat surface of one ring gear bolt. Force the differential case toward the dial indicator as far as possible and zero dial indicator with force still applied. Dial indicator should have a minimum of .200 inch travel. Force differential case away from the dial indicator as far as it will go. Repeat this procedure until the same reading is obtained. Record dial indicator reading. This reading indicates the amount of shims needed behind the differential side bearings to take up total clearance between the differential bearing and case. This reading will be used during pinion and ring gear backlash adjustment. 4. Remove differential case from the carrier. Do not remove the master differential bearings at this time. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Testing and Inspection > Page 2033 Differential Case: Service and Repair For limited slip & locking differential assemblies, refer to ``Ford Drive Axle w/Integral Carrier'' section for assembly procedures. For adjustment procedures on these differentials, refer to step 9 in this procedure. 1. Install differential case in a vise, then apply suitable lubricant to side gear thrust washers and to hubs and thrust face of the new side gears. 2. Assemble both side gears and apply suitable lubricant to the spherical washers and pinion mate gears, then assemble pinion mate gears and washers. 3. Install both side gears and thrust washers, then the pinion mate gears and washers to hold side gears in position. 4. Rotate side gears until holes of washers and pinion gears line up with holes of the case. If gears cannot be rotated by hand, install one of the axle shafts into the side gear spline and use a pipe wrench to turn shaft. 5. Line up gear holes with those of the differential case using a suitable drift, then install pinion mate shaft. Ensure lock pin hole of shaft is lined up with lock pin hole of case. 6. Install lock pin, then peen metal of case over pin to lock in position. The semi-float shaft riding bearing design uses a locking pin that is installed using a suitable wrench. Use a new lock pin and assemble finger tight. This prevents differential side gears and differential pinion mate gears from rotating in the case and dropping out when servicing the carrier section. A new lock pin should be installed after assembling the axle shafts. 7. Install ring gear to case, then the ring gear attaching screws. Torque ring gear attaching screws alternately to approximately 115 ft. lbs. on except model 30 axle or 45---60 ft. lbs on model 30 axle. 8. Install differential bearings onto case using suitable tool. 9. Install differential case assembly into carrier, less pinion, then mount suitable dial indicator on face of housing. 10. Locate tip of indicator on flat surface of one of the ring gear screw spot faces, then force differential assembly as far as possible in the direction towards the indicator. With force still applied, set indicator at zero. 11. Force differential assembly as far as it will go in the opposite direction. Repeat this step until the same reading is obtained, then record this reading. This reading will be the total amount of shims required, less preload, and will be calculated later during assembly. 12. Remove indicator and differential assembly from housing. Do not remove bearings from differential case at this time. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Dana/Spicer Integral - Rear Axle Assembly Differential Axle Housing: Service and Repair Dana/Spicer Integral - Rear Axle Assembly 1. Raise vehicle from floor and support with stand jacks under frame side rails. 2. Remove rear wheels. 3. Split rear universal joint. 4. Disconnect parking brake cable from equalizer rod and unfasten brake cable brackets from frame crossmember. 5. Disconnect hydraulic brake line connection at rear axle housing. 6. Loosen and move shock absorbers out of the way. 7. While supporting axle housing with hydraulic jack, remove spring clips and lower axle assembly to the floor. 8. Reverse the foregoing procedure to install the rear axle assembly, being sure to bleed the brake system when the installation is completed. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Dana/Spicer Integral - Rear Axle Assembly > Page 2038 Differential Axle Housing: Service and Repair Ford Integral Carrier Axle Disassembly, Ford Integral Carrier Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Dana/Spicer Integral - Rear Axle Assembly > Page 2039 Fig. 1 Disassembled view of Ford 6 3/4 inch ring gear axle Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Dana/Spicer Integral - Rear Axle Assembly > Page 2040 Fig. 2 Disassembled view of Ford 7 1/2 inch ring gear axle Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Dana/Spicer Integral - Rear Axle Assembly > Page 2041 Fig. 3 Exploded view of 8.8 & 10.25 inch ring gear axles (except models w/anti-lock brakes). 8.8 inch ring gear axle shown, 10.25 inch ring gear axle similar Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Dana/Spicer Integral - Rear Axle Assembly > Page 2042 Fig. 4 Exploded view of 8.8 inch ring gear axles. Models w/anti-lock brakes 1. Remove axle cover, Figs. 1 through 4, then wipe lubricant from internal working parts and visually inspect parts for wear or damage. 2. Rotate gears to check for any roughness, which indicates damaged bearings or gears. 3. Check ring gear teeth for signs of scoring, abnormal wear, nicks or chips. 4. On models with 8.8 or 10.25 inch ring gear, proceed as follows: a. Using dial indicator, check ring gear backlash and ring gear back face runout. Backlash should be .008---.015 inch and back face runout should be under .004 inch. b. Do not use contact pattern as a guide to check for noise. Check for proper gear set assembly using pinion depth gauge tool to determine correct pinion shim required to ensure acceptable running condition. 5. On models with 6 3/4 or 7 1/2 inch ring gear, test ring gear runout as follows: a. Install suitable dial indicator and zero indicator, then rotate ring gear and record reading. b. If reading exceeds .003 inch, check for improper torque of ring gear bolts or dirt between ring and case. 6. If reading still exceeds .003 inch after step 5b, diagnose ring gear runout as follows: a. Remove ring gear. 1987 Bronco II models with anti-lock brakes use an exciter ring located on the ring gear assembly. Removal of the exciter ring is not necessary when removing ring gear on this model. b. On models with 6 3/4 inch ring gear, install left case on right and tap them together, then place differential cups on differential bearing cone and roller. c. On all models, place differential assembly in carrier casting. On models with 6 3/4 inch ring gear, two bolts and nuts must be installed to hold case halves together. d. Install .265 inch shim on left side as guide. e. Install left bearing cap and tighten bolts finger tight. f. Install progressively larger shims on right side until largest shim selected can be assembled with a slight drag feel. Apply pressure toward left side to ensure that bearing cup is seated. g. Install right side bearing cap and torque differential bearing cap bolts to 70---80 ft. lbs., then rotate assembly to ensure free rotation. h. Check runout of differential case flange with dial indicator. If runout is within .003 inch, install new ring and pinion gear. If runout exceeds specifications, trouble is due to either a damaged case or worn bearings. i. Remove differential case from carrier and the differential bearings from case. j. Install new differential bearings on case hubs and install differential assembly in carrier less ring gear. k. Check case runout. If runout is within .003 inch, use new bearings for reassembly. If runout is still excessive, case is damaged and must be replaced. 7. Remove axle shafts. 8. Mark relationship of driveshaft end yoke and axle companion flange for proper assembly, then disconnect driveshaft at rear axle universal joint. 9. Install inch pound torque wrench on pinion nut and record torque required to maintain rotation of pinion through several turns. 10. Using suitable tools, hold companion flange and remove pinion nut. 11. Clean area around oil seal and place drain pan under seal. 12. Mark relationship of companion flange to pinion shaft for proper assembly, then, using suitable puller, remove companion flange. 13. Using suitable tool, remove pinion oil seal. 14. Mark one differential bearing cap to ensure proper positioning of caps during assembly. Do not interchange left and right bearing caps. 15. Loosen differential bearing cap bolts and bearing caps, noting direction of triangles on bearing caps for proper assembly. 16. Pry differential case, bearing cups and shims out until they are loose in bearing caps, then remove bearing caps and pry differential assembly from carrier. When using pry bar, place a wood block between pry bar and axle housing to protect casting face from damage. 17. Using suitable mallet, drive pinion out of front bearing cone and remove through rear of carrier casting. 18. Using suitable tools, remove pinion rear cone and roller bearing assembly, then, using micrometer, measure and record thickness of shim found under bearing cone. 19. Remove damaged pinion bearing cups from carrier by tapping alternately with brass drift on opposite sides of cups to prevent cups from cocking in casting. Axle Housing, Replace, Ford Integral Carrier 1. Remove four backing plate nuts from each side of axle and wire backing plate aside. 2. Remove vent hose from vent and vent from brake junction block on rear axle housing. 3. Remove brake line from clips on axle housing and remove brake junction block. Do not open brake lines when removing junction box. 4. Support rear axle housing on suitable jack and remove U-bolt nuts and plates. 5. Disconnect lower bolts on shock absorber mounting bracket and remove housing from vehicle. 6. Reverse procedure to install. Torque U-bolt nuts to 75-100 ft. lbs. on 1983 F-100-350 & Bronco; 75-105 ft. lbs. on 1983 E-100-150 and 1984-87 E-250; 75-115 ft. lbs. on 1984-87 models exc. F-250 4 2 chassis cab and E series; 150-180 ft. lbs. on 1983 E-250 and 1983-87 E-350; and 150-210 ft. lbs. on 1983 and 1986-87 F-350 and 1984-87 F-250 4 2 chassis cab. Torque shock absorber lower bolts to 40-60 ft. lbs. on Econoline models, and 40-64 ft. lbs. on all other models. Torque backing brake attaching bolts to 20-40 ft. lbs. on F-100-150 models, and 50-70 ft. lbs. on E-250 & F-250 models with 4050 lb. axle. No gaskets are required on brake backing plate. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Axle Housing > Component Information > Service and Repair > Dana/Spicer Integral - Rear Axle Assembly > Page 2043 Differential Axle Housing: Service and Repair Ford Removable Carrier 1. Raise and support vehicle. 2. Remove rear wheels and brake drums. 3. Remove rear wheel bearing retainer plate attaching nuts, then disconnect axle shafts from axle housing. 4. Mark driveshaft end yoke and U-joint flange for assembly reference, then disconnect driveshaft from flange. Mark position of cups to flange and remove driveshaft from transmission extension housing. Install a suitable seal installation tool into housing to prevent leakage. 5. Unfasten brake lines from retaining clips and disconnect vent tube, if equipped, from axle housing. 6. Remove brake backing plate assemblies from axle housing and wire aside. 7. Disconnect rear shock absorbers from lower mounts and position aside. 8. Lower axle slightly to reduce spring tension, then remove spring clips, U-bolt nuts and spring seat caps from each rear spring and lower axle assembly from vehicle. 9. On all models, reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Drivetrain - Lubricant Usage Fluid - Differential: Technical Service Bulletins Drivetrain - Lubricant Usage Article No. 89-8-16 ^ DRIVETRAIN - LUBRICATION USAGE ^ TRANSMISSION - MANUAL - LUBRICATION USAGE LIGHT TRUCK: 1980-89 BRONCO, ECONOLINE, F-150, F-250, F-350 1983-89 RANGER 1984-89 BRONCO II 1986-89 AEROSTAR ISSUE: A quick reference manual transmission fluid usage chart and a quick reference drivetrain lubrication usage chart for light trucks has been put together to assist technicians in the event service is required. FIGURE 1 FIGURE 2 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Drivetrain - Lubricant Usage > Page 2048 ACTION: Refer to the transmission fluid application chart in Figure 1 for the correct fluid usage. Refer to the drivetrain lubrication application chart in Figure 2 for the correct lubricant usage. PART NUMBER PART NAME CLASS D8DZ-19C547-A Standard Transmission BG Lubricant - 5 gallons C1AZ-19590-BA Long Life Lubricant B (molybdenum disulfide) - 14.5 ounces DOAZ-19584-AA Multi-Purpose Grease - 4 ounce B tube D7AZ-19584-AA Multi-Purpose Grease - 15 B ounce aerosol can XT-2-QDX Transmission Fluid (Mercon) - V quart can (pkg. of 12) C6AZ-19580-E Gear Oil (Dana axle) - 1 gallon AG C8AZ-19B546-A Additive Friction Modifier - 4 AM ounce bottle D7AZ-19590-A Disc Brake Caliper Slide AM Grease - 4 ounce tube E8TZ-19590-A Grease - 14.5 ounces B E1TZ-19590-A Automatic Hublock Grease - 5 B ounce tube E5RY-19C547-A Merkur Synthetic Manual B Transmission Fluid OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 5970 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Drivetrain - Lubricant Usage > Page 2049 Fluid - Differential: Technical Service Bulletins Front/Rear Drive Axles - Lubricant Drain/Fill Procedure Article No. 83-3-23 FRONT AND REAR DRIVE AXLES - LUBRICANT DRAIN AND FILL PROCEDURE LIGHT TRUCKS 1979-83 F100-350, BRONCO, E100-350, RANGER, BRONCO II The following is the recommended procedure for draining axle lubricant from front and/or rear driving axles on all light truck models. 1. Drive the vehicle for 10-15 miles at highway speed to warm axle lubricant to operating temperature and minimum viscosity. 2. Raise the vehicle on a hoist and place a drain pan under the axle to be drained. 3. Wire brush the filler plug area of the axle housing cover or carrier assembly to prevent possible entry of dirt, rust, etc. into the axle assembly. 4. Remove the axle lubricant fill plug. 5. Using a suitable suction-type utility pump (manual or powered), drain the axle lubricant from the axle by inserting the pump suction hose through axle filler plug hole down into the lowest portion of the axle carrier housing removing all the lubricant. 6. Fill the axle housing with the specified amount and type of lubricant as shown on the following specification charts. 7. Install the filler plug and torque as shown on the following specification charts. FRONT/REAR DRIVING AXLE SPECIFICATION CHARTS I. Filler Rug Torque Chart Axle Fill Plug Torque All Dana Front/Rear 20-30 Ft.Lbs. - Ford Built Rear Axles 25-50 Ft.Lbs. II. Axle Lubricant Capacities - Econoline Approximate Capacity (1) U.S. Pints (2) Ford Standard and Traction-Lok 5.5 (3) (E-100/150) Dana Standard and Limited Slip 6.0 (4) (E-250, Model 60/61-2) Dana Standard and Limited Slip 6.5 (4) (Model 70), Dual Rear Wheels Ford Standard and Traction-Lok 5.5 (E-250 Van) Dana Standard and Limited Slip 6.0 (4) (Model 61-1) Single Rear Wheels (1) Service refill capacities are determined by filling to the bottom of the filler hole. (2) All Ford Conventional and Traction-Lok Rear Axles Use ESP-M2C154-A All Dana Conventional and Limited-Slip Rear Axles - Use ESW-M2C105-A (3) Add 4 ounces of EST-M2C118-A (Friction Modifier C8AZ-19B546-A) for complete fill of Ford TractionLok axle. (4) Add 4 ounces of EST-M2C118-A (Friction Modifier C8AZ-19B546-A) for complete refill of Dana Rear Limited-Slip Axle. III. Axle Lubricant Capacities - Bronco Chart Approximate Capacity (1) U.S. Pints Front Axle (5) Dana 3.8 (3) Rear Axle (4) Ford 5.5 (2) (1) Refill Capacity is determined by filling to the bottom of the filler hole. (2) All Ford Conventional and Traction-Lok Rear Axles Use ESP-M2C154-A. (3) All Dana Conventional and Limited-Slip Front Drive Axles - Use ESW-M2C105-A. (4) Add 4 ounces of EST-M2C118-A (Friction Modifier C8AZ-19B546-A) for complete fill of Ford TractionLok Axle (1979-1982). Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Technical Service Bulletins > Drivetrain - Lubricant Usage > Page 2050 (5) Add 2 ounces of EST-M2C118-A (Friction Modifier C8AZ-19B546-A) for complete refill of Dana Front Limited-Slip Axle. IV. Axle Lubricant Capacities - F100 - F350 (4x2/4x4) Approximate Capacity (1) U.S. Measure Axle Model (4) Truck Type (Pints) Ford 8.8" and 9" F100/150/250 5.5 (3) Dana 44-IFS (Front Axle) F150/250 (4x4) 3.8 Dana 60 (Rear) F250 6.0 Dana 61-2 (Rear) F250 6.0 Dana 50-IFS (Front Axle) F250/350 (4x4) Heavy 4.1 Duty & Snow Plow Dana 70 (Rear) F350 DRW Chassis Cab 6.5 Dana 70 HD (Rear) F350 DRW Regular Cab 7.4 Dana 61-1 (Rear F250/350 SRW 6.0 (1) Service refill capacities are determined by filling to the bottom of the filler hole. (2) Add EST-M2C118-A (Friction Modifier Part No. C8AZ-19B546-A) for complete refill of Dana LimitedSlip axles. Add 4 ounces for F250/350 Rear. For F150 & F250 4x4 add 2 ounces to front axle. (3) Add 4 ounces of EST-M2C118-A (Friction Modifier C8AZ-19B546-A) for complete fill of Ford TractionLok Axle (1979-1982). (4) All Ford Conventional and Traction-Lok Rear Axles Use ESP-M2C154-A. All Dana Conventional and Limited-Slip Front/Rear Axles - Use ESW-M2C105-A. V. Axle Lubricant Capacities - Ranger 4x2/4x4, Bronco II Approximate Capacities U.S. Imperial Measure Measure (Pints) (Pints) Liters Rear Ford 6-3/4 Ring Gear (1)(4) 3.0 2.5 1.4 Rear Ford 7.5 Ring Gear (2)(4) 5.0 (6) 4.2 2.4 Dana 28 Front Axle (4x4 Only)(3)(5) 1.0 (7) 0.83 0.45 Bronco II Ford 7.5 Ring Gear(2)(4) 5.5 (6) 4.6 2.6 (1) Fill to 3/8 in. +/- 1/8 in. (9.5 mm +/- 3 mm) below bottom of fill hole. Base GVW axle with 2.0L engine and 2.3L engine with automatic. (2) Fill to 1/2 in. +/- 1/8 in. (12.7 mm t 3 mm) below bottom of fill hole. Optional GVW or 2.3L engine. (3) Fill to 1/2 in. +/- 1/8 in. (12.7 mm + 3 mm) below bottom of fill hole. (4) All Ford Conventional and Traction-Lok Rear Axles Use ESP-M2C154-A. (5) All Dana Conventional and Limited-Slip Front Axles - Use ESW-M2C105-A. (6) Add 4 ounces of EST-M2C118-A (Friction Modifier C8AZ-19B546-A) for complete fill of Ford TractionLok Axle. (7) Add 1/2 ounce of EST-M2C118-A (Friction Modifier C8AZ-19B546-A) for complete refill of Dana Front Limited-Slip Axle. PART NUMBER PART NAME CLASS E0AZ-19580-A Lubricant-ESP-M2C154-A AM C6AZ-19580-E Lubricant-ESW-M2C105-A AG C8AZ-19B546-A Friction Modifier-EST-M2C118-A A OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications Fluid - Differential: Capacity Specifications TYPE: Standard 90 HP Limited-Slip 90 HP* CAPACITY, Refill: Front: All models 4.0 pt (US) LIMITED-SLIP OR TRACTION-LOK IDENTIFICATION: Letter & number on plate on door lock pillar Rear: Dana 60 5.0 pt (US) Dana 61 6.0 pt (US) 1982 70 HD 7.4 pt (US) 1981 Econoline w/Dana 70 7.0 pt (US) Others 6.5 pt (US) Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications > Capacity Specifications > Page 2053 Fluid - Differential: Fluid Type Specifications BL Self-adjusting Brake Lubricant EC Ethylene Glycol Coolant Mix 50/50 with water to at least -20°F (-29°C) protection EP Extreme Pressure Gear Lubricant Ford Part No. D8DZ-19C547-A FA Automatic Transmission Fluid, Type F GL-5 Gear Oil, API Service GL-5 HBH Hydraulic Brake Fluid, Extra Heavy-Duty HP Hypoid Gear Oil Ford Part No. E0AZ-19580-A HP* Hypoid Gear Oil for Limited-Slip or Traction-Lok Differential LM Lithium Grease, with Polyethylene LS Steering Gear Lubricant MA MERCONAutomatic Transmission Fluid MH Manifold Heat Valve Solvent SG Motor Oil, API Service SG Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Testing and Inspection > Bearing Cups Pinion Bearing: Testing and Inspection Bearing Cups Check bearing cups for rings, galling or erratic wear patterns. The bearing cups must be solidly seated. Check by attempting to insert .0015 inch feeler gauge between cups and bottoms of bores. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Testing and Inspection > Bearing Cups > Page 2058 Pinion Bearing: Testing and Inspection Companion Flange Be sure that flat machined surfaces and the bearing cup sockets of the flange have not been damaged in removing driveshaft or in removing flange from axle. The edge of the flange that contacts the oil slinger or pinion front bearing must be smooth. Roughness aggravates backlash noises and causes wear on the slinger with a resultant loss in drive pinion bearing preload. The seal surface should be perfectly smooth or leakage will result. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Testing and Inspection > Bearing Cups > Page 2059 Pinion Bearing: Testing and Inspection Cone & Roller Assemblies When operated in the cups, the cone and roller assemblies must turn without any roughness. Examine roller ends for wear. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Testing and Inspection > Bearing Cups > Page 2060 Pinion Bearing: Testing and Inspection Differential Bearing Adjusters Test fit of bearing adjusters in their threads with bearing caps installed. Ensure that bearing caps are on sides that they were machined to fit. The faces of the adjusters that contact the bearing cups must be smooth and square. Examine threads in carrier if their fit is not proper and replace any adjuster with a damaged face or threads. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Testing and Inspection > Bearing Cups > Page 2061 Pinion Bearing: Testing and Inspection Pinion Retainer Inspect visually for damage. Ensure that pinion bearing cups are seated. Ensure that there are no chips or burrs on mounting flange. Clean all lubricant passages. If pinion bearing cups were removed, examine bores in retainer carefully. Any nicks or burrs in these bores must be removed to permit proper seating of cups. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Testing and Inspection > Page 2062 Pinion Bearing: Adjustments Fig. 4 Shim replacement for preload adjustment Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Testing and Inspection > Page 2063 Fig. 5 Final pinion depth check 1. Install preload shims and slinger, if equipped, onto the pinion. 2. Install bearing cone assembly using suitable tool. 3. Install end yoke, washer and new pinion nut. Torque nut to approximately 250 ft. lbs. on except model 30 axle or 200---220 ft. lbs. on model 30 axle. 4. Rotate pinion using a suitable torque wrench. Rotating torque should be 20---40 inch lbs. To increase preload, remove shims from drive pinion. To decrease preload, add shims to pinion, Fig. 4. 5. Install suitable gauge tube in housing, then the bearing caps and cap attaching bolts, Fig. 5. Torque cap attaching bolts to 80---90 ft. lbs. on except model 30 axle or 35---50 ft. lbs. on model 30 axle. 6. Insert proper final check gauge block on top of pinion face under the gauge tube, Fig. 5. Place thumb on gauge block to ensure block is level. 7. Insert feeler gauge or shims between gauge tube and final check gauge block until slight drag is felt. 8. The reading in step 7 should be .020 inch added to the drive pinion etching, which could be plus (+) or minus ( - ) with a tolerance of .002 inch. If the distance must be increased, remove shims from beneath the inner pinion bearing cup. If the distance must be decreased, add shims beneath the inner pinion bearing cup. 9. With drive pinion at the correct depth, remove the yoke, nut and washer using a suitable tool. 10. Apply suitable lubricant to oil seal, then install drive pinion oil seal using a suitable installer. Ensure seal spring is properly installed after seal installation. 11. Install yoke using suitable tool, then the washer and nut. Torque nut to approximately 250 ft. lbs. on except model 30 axle or 200---220 ft. lbs. on model 30 axle. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle Pinion Bearing: Service and Repair Dana/Spicer, Rear Axle Pinion Bearing Cup Installation, DANA/SPICER, REAR AXLE 1. Place inner and outer bearing cups into carrier bore. 2. Install suitable inner bearing cup replacer tool on the inner bearing cup. 3. Install suitable outer bearing cup replacer tool on the outer bearing cup. 4. Install suitable threaded draw bar into the replacer tools, then tighten the draw bar to install cups into carrier bore. Pinion Bearing Preload & Final Depth Check, REAR AXLE Fig. 4 Shim replacement for preload adjustment Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle > Page 2066 Fig. 5 Final pinion depth check 1. Install preload shims and slinger, if equipped, onto the pinion. 2. Install bearing cone assembly using suitable tool. 3. Install end yoke, washer and new pinion nut. Torque nut to approximately 250 ft. lbs. on except model 30 axle or 200---220 ft. lbs. on model 30 axle. 4. Rotate pinion using a suitable torque wrench. Rotating torque should be 20---40 inch lbs. To increase preload, remove shims from drive pinion. To decrease preload, add shims to pinion, Fig. 4. 5. Install suitable gauge tube in housing, then the bearing caps and cap attaching bolts, Fig. 5. Torque cap attaching bolts to 80---90 ft. lbs. on except model 30 axle or 35---50 ft. lbs. on model 30 axle. 6. Insert proper final check gauge block on top of pinion face under the gauge tube, Fig. 5. Place thumb on gauge block to ensure block is level. 7. Insert feeler gauge or shims between gauge tube and final check gauge block until slight drag is felt. 8. The reading in step 7 should be .020 inch added to the drive pinion etching, which could be plus (+) or minus ( - ) with a tolerance of .002 inch. If the distance must be increased, remove shims from beneath the inner pinion bearing cup. If the distance must be decreased, add shims beneath the inner pinion bearing cup. 9. With drive pinion at the correct depth, remove the yoke, nut and washer using a suitable tool. 10. Apply suitable lubricant to oil seal, then install drive pinion oil seal using a suitable installer. Ensure seal spring is properly installed after seal installation. 11. Install yoke using suitable tool, then the washer and nut. Torque nut to approximately 250 ft. lbs. on except model 30 axle or 200---220 ft. lbs. on model 30 axle. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle > Page 2067 Pinion Bearing: Service and Repair Ford Removable Backlash & Differential Bearing Preload Adjustment 1. Remove adjusting nut locks and loosen differential bearing cap bolts, then torque cap bolts to approximately 20 ft. lbs. Left adjusting nut is on ring gear side of carrier and right adjusting nut is on pinion side. 2. Loosen right nut until it is away from cup and tighten left nut until ring gear is just forced into position with zero backlash, then rotate pinion several revolutions to ensure that no binding is evident. 3. Check right nut to ensure that it is still loose, then install dial indicator. 4. Tighten right nut until it just contacts bearing cup, then set dial indicator to zero and apply pressure to bearings by tightening right nut until indicator reads .008---.012 inch. 5. Turn pinion gear several times in each direction to seat bearings in cups and ensure that no binding is evident, then torque bearing caps to 70---80 ft. lbs. 6. Measure backlash on several teeth around ring gear. 7. If backlash varies by more than .004 inch between any two teeth, loosen one adjusting nut and tighten opposite nut an equal amount to move ring gear away from or toward pinion. Tightening left nut moves ring gear into pinion to decrease backlash while tightening right nut moves ring gear away. When moving adjusting nuts, final movement should always be made in a tightening direction. Assuming left nut had to be loosened one notch, loosen nut two notches, then tighten one notch. 8. Ensure that case spread remains within specifications as previously described. 9. Perform teeth pattern check as described under ``General Axle Service.'' If backlash is correct and gross pattern error results, recheck pinion shim selection. Drive Pinion & Bearing Retainer, FORD, REMOVABLE CARRIER, Fig. 7 Installing Pinion And Retainer Assembly Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle > Page 2068 Fig. 8 Installing Companion Flange Fig. 9 Checking Pinion Bearing Preload A new ring gear and drive pinion should always be installed as a matched set. Ensure that identifying numbers on ring gear and head of drive pinion are identical. 1. Using suitable tool, install pinion rear bearing cone on pinion shaft, then position new spacer on pinion shaft. 2. Place bearing retainer on drive pinion shaft and install front bearing cone and roller, then, using tool T57L-4621-B or equivalent, press bearing cone and roller into position, being careful not to crush collapsible spacer. 3. Lubricate O-ring with suitable lubricant, install into groove in pinion retainer, and snap into place. Then lubricate front and rear pinion bearings. 4. Position selected shim on carrier housing and install pinion and retainer assembly, being careful not to pinch O-ring, Fig. 7. 5. Install pinion retainer attaching bolts, torquing to 30---40 ft. lbs., then install oil slinger, if equipped. 6. Using suitable tool, install new pinion oil seal in bearing retainer. 7. Install companion flange, Fig. 8. 8. Apply small amount of suitable lubricant to flange side of new pinion nut and start nut on drive pinion shaft. 9. Hold flange with suitable tool and tighten flange nut. 10. Check pinion bearing preload, Fig. 9. Correct preload is obtained when torque required to rotate pinion in retainer is 8---14 inch lbs. for original bearing or 16---29 inch lbs. for new bearing. If torque required to rotate pinion is less than specified, tighten pinion shaft nut a little at a time until proper preload is obtained. Do not over tighten nut. If excessive preload is obtained as a result of over tightening, replace collapsible bearing spacer. Do not back off pinion shaft nut to establish pinion bearing preload. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle > Page 2069 Pinion Bearing Cups, Replace, FORD REMOVABLE CARRIER Do not remove drive pinion bearing cups from the retainer unless cups are worn or damaged. 1. Using suitable puller, remove bearing cups. 2. Using tool T71P-4616-A or equivalent, install new bearing cups. 3. Check seating of cups by attempting to insert a .0015 inch feeler gauge between cup and bottom of bore. Cone and roller assemblies should be replaced whenever cups are replaced. Selecting Correct Pinion Shim, FORD REMOVABLE CARRIER Fig. 5 Removable carrier 9 inch ring gear axle pinion depth tool gauge Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle > Page 2070 Fig. 6 Using pinion depth gauge tool When the ring gear and drive pinion or pinion bearings are replaced, the correct pinion shim thickness must be determined using tool T79P-4020-A or equivalent. 1. Select proper rear pinion bearing aligning adapter and gauge disc and slide these adapters over screw or threaded shaft, Fig. 5. 2. Install gauge block on threaded shaft and tighten securely, Fig. 6 (1). 3. Place assembly and rear drive pinion bearing into pinion bearing retainer assembly, then install front pinion bearing and screw handle onto threaded shaft, tapered end into front pinion bearing, Fig. 6 (1) and (2). Flat end of handle has 3/8 inch hole cut in it so that an inch pound torque wrench may be used to obtain proper pinion bearing preload. 4. Install pinion bearing retainer assembly into carrier, less shim, torquing attaching bolts to 30---40 ft. lbs. 5. Rotate gauge block so that it rests against pilot boss, Fig. 6 (3). 6. Using feeler gauge, measure distance between gauge block and gauge tube, Fig. 6 (4). Insert blade directly along gauge block top to ensure a correct reading. Fit should be a slight drag-type feeling. 7. Select proper shim according to feeler gauge reading, Fig. 6. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle > Page 2071 Pinion Bearing: Service and Repair Ford, Removable Carrier, Disassembly Fig. 3 Removing Pinion Shaft Nut Fig. 4 Removing Companion Flange 1. Remove drive pinion shaft nut, Fig. 3. 2. Remove companion flange from drive pinion shaft, Fig. 4. 3. Using suitable puller, remove pinion seal. 4. Remove the pinion, bearing, and retainer assembly from carrier housing. Extreme care must be taken not to damage mounting surfaces of retainer and carrier. 5. Place protective sleeve on pinion pilot bearing surface and press drive pinion shaft out of pinion retainer. 6. Using tool T71P-4621-B or equivalent, press pinion shaft out of pinion rear bearing cone. 7. Clean and inspect all parts as described in ``General Axle Service.'' Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle > Page 2072 Pinion Bearing: Service and Repair Pinion Bearing Cup Installation 1. Place inner and outer bearing cups into carrier bore. 2. Install suitable inner bearing cup replacer tool on the inner bearing cup. 3. Install suitable outer bearing cup replacer tool on the outer bearing cup. 4. Install suitable threaded draw bar into the replacer tools, then tighten the draw bar to install cups into carrier bore. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Technical Service Bulletins > Rear Axle - Pinion Angle Adjustments Pinion Gear: Technical Service Bulletins Rear Axle - Pinion Angle Adjustments Article No. 85-5-28 REAR AXLE PINION ANGLE ADJUSTMENTS LIGHT TRUCK 1976-85 E & F 100-350 AND BRONCO Whenever the rear axle pinion angle requires adjustment to bring it into specification, the following tapered shims should be installed as outlined in the 1985 Light Truck Shop Manual, Section 14-31-2. Part Number Part Number Angle Degree Application Class C3TZ-5A313-A 2.5" Wide Shim 2 F-100/150 C C3TZ-5A313-E (Ford Axles) 3 Bronco R E100/150 C6TZ-5A313-B 3.0" Wide Shim 3 F-250/350 BM (Dana Axles) E-250/350 WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Technical Service Bulletins > Rear Axle - Pinion Angle Adjustments > Page 2077 Pinion Gear: Technical Service Bulletins Differential Pinion Bolt - Removal Aid Article No. 84-6-15 AXLE - FORD-BUILT CAST CENTER AXLES - AID TO BOLT REMOVAL PROCEDURE FOR DIFFERENTIAL PINION SHAFT LOCK BOLT FORD 1977-84 FORD CARLINES WITH 7.5", 8.5", 8.7", 8.8" REAR AXLES LINCOLN-MERCURY 1977-84 LINCOLN-MERCURY CARLINES WITH 7.5", 8.5", 8.7", 8.8" REAR AXLES LIGHT TRUCKS 1977-84 LIGHT TRUCKS WITH 7.5", 8.8" REAR AXLES The subject bolt head may round off during removal with a conventional wrench or socket. To eliminate this condition, a socket type wrench may be made from a 3/8-inch Allen head bolt and a steel rod. FIGURE 12 Cut the Allen head from the bolt and weld the head to the 6" rod. The rod will serve as a handle (Figure 12). In addition, the recess in the Allen head fits the 5/16-inch head in the differential pinion shaft lock bolt precisely. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Technical Service Bulletins > Page 2078 Pinion Gear: Testing and Inspection Examine drive pinion and ring gear teeth for scoring or signs of excessive wear. Worn gears cannot be rebuilt to correct a noisy condition. Gear scoring and flaking are the result of excessive shock loading or the use of improper lubricant. Scored gears cannot be reused. Examine teeth and thrust surfaces of differential gears. Wear on hub of differential side gears may cause a chucking noise known as chuckle, when the vehicle is operated at low speeds. Wear of splines, thrust surfaces or thrust washers may contribute to excessive drive line backlash. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Adjustments > Depth Gauge Check Pinion Gear: Adjustments Depth Gauge Check If any of the gauge surfaces become nicked, the high spots should be removed using an oil stone. 1. Install a new rear pinion bearing over a suitable aligning adapter, then position into the pinion bearing retainer assembly. 2. Place front of pinion bearing into the bearing cup, then assemble the handle onto the screw and hand tighten. The square drive in the handle of the tool is to be used for obtaining the proper pinion bearing preload. Set preload to 20---40 inch lbs. 3. Center suitable gauge tube into the differential bearing bore, then install the differential bearing caps. 4. Using a feeler gauge tool or shims, select the thickest shim that will enter between the gauge tube and gauge block. Insert feeler gauge directly along the gauge block to ensure a correct reading. If the service pinion gear is marked with a plus (+) reading, this amount should be subtracted from the thickness dimension obtained in step 4. If the service pinion gear is marked with a minus ( - ) reading, this amount should be added to the thickness dimension obtained in step 4. 5. Remove inner pinion bearing cup and install the correct number of shims in the carrier bore. 6. Install bearing cup and oil slinger, if equipped, on the pinion, then press on bearing using a suitable tool. If a baffle or slinger is used, replace with a new one during assembly. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Adjustments > Depth Gauge Check > Page 2081 Pinion Gear: Adjustments Drive Pinion Depth of Mesh Setting Fig. 3 Shim setting chart Ring gears and pinions are supplied in matched sets only. Matched numbers on both the pinion and ring gear are etched for verification. On the face of each pinion there is etched either a plus or a minus number, or ``0,'' which indicates the best running position for each particular gear set. This dimension is controlled by shimming behind the inner pinion bearing cup. A pinion etched with a +3 would require .003 inch less shims that a pinion etched ``0.'' A pinion etched - 3 would require .003 inch more shims than a pinion etched ``0.'' If the etched figure is ``0'' the shim pack will remain the same. Refer to chart, Fig. 3. Shims are available in thicknesses of .003 inch, .005 inch, .010 inch and .030 inch. If old ring and pinion set is to be reused, measure the old shim pack and build a new shim pack to the same dimension. If a baffle is used in the axle assembly, it is considered a part of the shim pack. Measure each shim separately with a micrometer and add together to get the total shim pack thickness from the original build up. If a new gear set is being used, notice the (+) or ( - ) etching on both the new and old pinion and adjust thickness of new shim pack to compensate for the difference of these two figures. For example, if the old pinion reads +2 and the new pinion is - 2, add .004 inch shims to the original shim pack. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Adjustments > Depth Gauge Check > Page 2082 Pinion Gear: Adjustments Pinion Bearing Preload & Final Depth Check Fig. 4 Shim replacement for preload adjustment Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Adjustments > Depth Gauge Check > Page 2083 Fig. 5 Final pinion depth check 1. Install preload shims and slinger, if equipped, onto the pinion. 2. Install bearing cone assembly using suitable tool. 3. Install end yoke, washer and new pinion nut. Torque nut to approximately 250 ft. lbs. on except model 30 axle or 200---220 ft. lbs. on model 30 axle. 4. Rotate pinion using a suitable torque wrench. Rotating torque should be 20---40 inch lbs. To increase preload, remove shims from drive pinion. To decrease preload, add shims to pinion, Fig. 4. 5. Install suitable gauge tube in housing, then the bearing caps and cap attaching bolts, Fig. 5. Torque cap attaching bolts to 80---90 ft. lbs. on except model 30 axle or 35---50 ft. lbs. on model 30 axle. 6. Insert proper final check gauge block on top of pinion face under the gauge tube, Fig. 5. Place thumb on gauge block to ensure block is level. 7. Insert feeler gauge or shims between gauge tube and final check gauge block until slight drag is felt. 8. The reading in step 7 should be .020 inch added to the drive pinion etching, which could be plus (+) or minus ( - ) with a tolerance of .002 inch. If the distance must be increased, remove shims from beneath the inner pinion bearing cup. If the distance must be decreased, add shims beneath the inner pinion bearing cup. 9. With drive pinion at the correct depth, remove the yoke, nut and washer using a suitable tool. 10. Apply suitable lubricant to oil seal, then install drive pinion oil seal using a suitable installer. Ensure seal spring is properly installed after seal installation. 11. Install yoke using suitable tool, then the washer and nut. Torque nut to approximately 250 ft. lbs. on except model 30 axle or 200---220 ft. lbs. on model 30 axle. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle Pinion Gear: Service and Repair Dana/Spicer, Rear Axle Depth Gauge Check, Dana/Spicer, Rear Axle If any of the gauge surfaces become nicked, the high spots should be removed using an oil stone. 1. Install a new rear pinion bearing over a suitable aligning adapter, then position into the pinion bearing retainer assembly. 2. Place front of pinion bearing into the bearing cup, then assemble the handle onto the screw and hand tighten. The square drive in the handle of the tool is to be used for obtaining the proper pinion bearing preload. Set preload to 20---40 inch lbs. 3. Center suitable gauge tube into the differential bearing bore, then install the differential bearing caps. 4. Using a feeler gauge tool or shims, select the thickest shim that will enter between the gauge tube and gauge block. Insert feeler gauge directly along the gauge block to ensure a correct reading. If the service pinion gear is marked with a plus (+) reading, this amount should be subtracted from the thickness dimension obtained in step 4. If the service pinion gear is marked with a minus ( - ) reading, this amount should be added to the thickness dimension obtained in step 4. 5. Remove inner pinion bearing cup and install the correct number of shims in the carrier bore. 6. Install bearing cup and oil slinger, if equipped, on the pinion, then press on bearing using a suitable tool. If a baffle or slinger is used, replace with a new one during assembly. Drive Pinion Depth of Mesh Setting, Dana/Spicer, Rear Axle Fig. 3 Shim setting chart Ring gears and pinions are supplied in matched sets only. Matched numbers on both the pinion and ring gear are etched for verification. On the face of each pinion there is etched either a plus or a minus number, or ``0,'' which indicates the best running position for each particular gear set. This dimension is controlled by shimming behind the inner pinion bearing cup. A pinion etched with a +3 would require .003 inch less shims that a pinion etched ``0.'' A pinion etched - 3 would require .003 inch more shims than a pinion etched ``0.'' If the etched figure is ``0'' the shim pack will remain the same. Refer to chart, Fig. 3. Shims are available in thicknesses of .003 inch, .005 inch, .010 inch and .030 inch. If old ring and pinion set is to be reused, measure the old shim pack and build a new shim pack to the same dimension. If a baffle is used in the axle assembly, it is considered a part of the shim pack. Measure each shim separately with a micrometer and add together to get the total shim pack thickness from the original build up. If a new gear set is being used, notice the (+) or ( - ) etching on both the new and old pinion and adjust thickness of new shim pack to compensate for the difference of these two figures. For example, if the old pinion reads +2 and the new pinion is - 2, add .004 inch shims to the original shim pack. Pinion Bearing Preload & Final Depth Check, Rear Axle Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle > Page 2086 Fig. 4 Shim replacement for preload adjustment Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle > Page 2087 Fig. 5 Final pinion depth check 1. Install preload shims and slinger, if equipped, onto the pinion. 2. Install bearing cone assembly using suitable tool. 3. Install end yoke, washer and new pinion nut. Torque nut to approximately 250 ft. lbs. on except model 30 axle or 200---220 ft. lbs. on model 30 axle. 4. Rotate pinion using a suitable torque wrench. Rotating torque should be 20---40 inch lbs. To increase preload, remove shims from drive pinion. To decrease preload, add shims to pinion, Fig. 4. 5. Install suitable gauge tube in housing, then the bearing caps and cap attaching bolts, Fig. 5. Torque cap attaching bolts to 80---90 ft. lbs. on except model 30 axle or 35---50 ft. lbs. on model 30 axle. 6. Insert proper final check gauge block on top of pinion face under the gauge tube, Fig. 5. Place thumb on gauge block to ensure block is level. 7. Insert feeler gauge or shims between gauge tube and final check gauge block until slight drag is felt. 8. The reading in step 7 should be .020 inch added to the drive pinion etching, which could be plus (+) or minus ( - ) with a tolerance of .002 inch. If the distance must be increased, remove shims from beneath the inner pinion bearing cup. If the distance must be decreased, add shims beneath the inner pinion bearing cup. 9. With drive pinion at the correct depth, remove the yoke, nut and washer using a suitable tool. 10. Apply suitable lubricant to oil seal, then install drive pinion oil seal using a suitable installer. Ensure seal spring is properly installed after seal installation. 11. Install yoke using suitable tool, then the washer and nut. Torque nut to approximately 250 ft. lbs. on except model 30 axle or 200---220 ft. lbs. on model 30 axle. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle > Page 2088 Pinion Gear: Service and Repair Ford Drive Axle W/ Removable Carrier Backlash & Differential Bearing Preload Adjustment 1. Remove adjusting nut locks and loosen differential bearing cap bolts, then torque cap bolts to approximately 20 ft. lbs. Left adjusting nut is on ring gear side of carrier and right adjusting nut is on pinion side. 2. Loosen right nut until it is away from cup and tighten left nut until ring gear is just forced into position with zero backlash, then rotate pinion several revolutions to ensure that no binding is evident. 3. Check right nut to ensure that it is still loose, then install dial indicator. 4. Tighten right nut until it just contacts bearing cup, then set dial indicator to zero and apply pressure to bearings by tightening right nut until indicator reads .008---.012 inch. 5. Turn pinion gear several times in each direction to seat bearings in cups and ensure that no binding is evident, then torque bearing caps to 70---80 ft. lbs. 6. Measure backlash on several teeth around ring gear. 7. If backlash varies by more than .004 inch between any two teeth, loosen one adjusting nut and tighten opposite nut an equal amount to move ring gear away from or toward pinion. Tightening left nut moves ring gear into pinion to decrease backlash while tightening right nut moves ring gear away. When moving adjusting nuts, final movement should always be made in a tightening direction. Assuming left nut had to be loosened one notch, loosen nut two notches, then tighten one notch. 8. Ensure that case spread remains within specifications as previously described. 9. Perform teeth pattern check as described under ``General Axle Service.'' If backlash is correct and gross pattern error results, recheck pinion shim selection. Drive Pinion & Bearing Retainer, Disassembly Fig. 3 Removing Pinion Shaft Nut Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle > Page 2089 Fig. 4 Removing Companion Flange 1. Remove drive pinion shaft nut, Fig. 3. 2. Remove companion flange from drive pinion shaft, Fig. 4. 3. Using suitable puller, remove pinion seal. 4. Remove the pinion, bearing, and retainer assembly from carrier housing. Extreme care must be taken not to damage mounting surfaces of retainer and carrier. 5. Place protective sleeve on pinion pilot bearing surface and press drive pinion shaft out of pinion retainer. 6. Using tool T71P-4621-B or equivalent, press pinion shaft out of pinion rear bearing cone. 7. Clean and inspect all parts as described in ``General Axle Service.'' Drive Pinion & Bearing Retainer, Ford, Removable Carrier, Fig. 7 Installing Pinion And Retainer Assembly Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle > Page 2090 Fig. 8 Installing Companion Flange Fig. 9 Checking Pinion Bearing Preload A new ring gear and drive pinion should always be installed as a matched set. Ensure that identifying numbers on ring gear and head of drive pinion are identical. 1. Using suitable tool, install pinion rear bearing cone on pinion shaft, then position new spacer on pinion shaft. 2. Place bearing retainer on drive pinion shaft and install front bearing cone and roller, then, using tool T57L-4621-B or equivalent, press bearing cone and roller into position, being careful not to crush collapsible spacer. 3. Lubricate O-ring with suitable lubricant, install into groove in pinion retainer, and snap into place. Then lubricate front and rear pinion bearings. 4. Position selected shim on carrier housing and install pinion and retainer assembly, being careful not to pinch O-ring, Fig. 7. 5. Install pinion retainer attaching bolts, torquing to 30---40 ft. lbs., then install oil slinger, if equipped. 6. Using suitable tool, install new pinion oil seal in bearing retainer. 7. Install companion flange, Fig. 8. 8. Apply small amount of suitable lubricant to flange side of new pinion nut and start nut on drive pinion shaft. 9. Hold flange with suitable tool and tighten flange nut. 10. Check pinion bearing preload, Fig. 9. Correct preload is obtained when torque required to rotate pinion in retainer is 8---14 inch lbs. for original bearing or 16---29 inch lbs. for new bearing. If torque required to rotate pinion is less than specified, tighten pinion shaft nut a little at a time until proper preload is obtained. Do not over tighten nut. If excessive preload is obtained as a result of over tightening, replace collapsible bearing spacer. Do not back off pinion shaft nut to establish pinion bearing preload. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle > Page 2091 Selecting Correct Pinion Shim, Ford Removable Carrier Fig. 5 Removable carrier 9 inch ring gear axle pinion depth tool gauge Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Dana/Spicer, Rear Axle > Page 2092 Fig. 6 Using pinion depth gauge tool When the ring gear and drive pinion or pinion bearings are replaced, the correct pinion shim thickness must be determined using tool T79P-4020-A or equivalent. 1. Select proper rear pinion bearing aligning adapter and gauge disc and slide these adapters over screw or threaded shaft, Fig. 5. 2. Install gauge block on threaded shaft and tighten securely, Fig. 6 (1). 3. Place assembly and rear drive pinion bearing into pinion bearing retainer assembly, then install front pinion bearing and screw handle onto threaded shaft, tapered end into front pinion bearing, Fig. 6 (1) and (2). Flat end of handle has 3/8 inch hole cut in it so that an inch pound torque wrench may be used to obtain proper pinion bearing preload. 4. Install pinion bearing retainer assembly into carrier, less shim, torquing attaching bolts to 30---40 ft. lbs. 5. Rotate gauge block so that it rests against pilot boss, Fig. 6 (3). 6. Using feeler gauge, measure distance between gauge block and gauge tube, Fig. 6 (4). Insert blade directly along gauge block top to ensure a correct reading. Fit should be a slight drag-type feeling. 7. Select proper shim according to feeler gauge reading, Fig. 6. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Testing and Inspection > Gears Ring Gear: Testing and Inspection Gears Examine drive pinion and ring gear teeth for scoring or signs of excessive wear. Worn gears cannot be rebuilt to correct a noisy condition. Gear scoring and flaking are the result of excessive shock loading or the use of improper lubricant. Scored gears cannot be reused. Examine teeth and thrust surfaces of differential gears. Wear on hub of differential side gears may cause a chucking noise known as chuckle, when the vehicle is operated at low speeds. Wear of splines, thrust surfaces or thrust washers may contribute to excessive drive line backlash. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Testing and Inspection > Gears > Page 2097 Ring Gear: Testing and Inspection Runout 1987 models equipped with anti-lock brakes incorporate a multi-tooth exciter ring which is pressed on the differential case located behind the ring gear assembly. Do not remove exciter ring to measure ring gear runout. A space is provided between the exciter ring and ring gear to measure ring gear runout. If ring gear runout during disassembly exceeded specifications, the condition may be caused by a warped gear, or distorted or damaged case or foreign matter trapped between differential case halves or under ring gears. To determine cause of excessive runout, assemble differential case without ring gear, then check as described below. Install case in differential carrier without ring gear attached. Install bearing caps and adjuster nuts and tighten cap bolts to specifications. Tighten adjuster nuts to center differential side bearing. Mount a dial indicator and check runout of case flange and ring gear pilot. If runout at either point is excessive, install a new differential case. If runout is within specification, the ring gear is out of specification. When performing this check on a locking differential case the four compression springs within the case should be temporarily removed. This will prevent a false runout reading due to distortion caused by the springs forcing the case apart. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Adjustments > Assembly of Differential Into Housing Ring Gear: Adjustments Assembly of Differential Into Housing Ring Gear & Pinion Backlash 1. Position differential assembly, with pinion installed, into housing. Ensure master bearings are still assembled in case. 2. Install dial indicator on carrier housing in same location as when spreading case. 3. Force ring gear into mesh with pinion, then set dial indicator to ``0'' while maintaining force on differential case. 4. Force ring gear away from pinion gear and note dial reading. Repeat sequence until same indicator reading is obtained. This measurement indicates amount of shims needed between differential case and bearings on the ring gear side. 5. Remove dial indicator and differential case from carrier, then the master bearings from differential case. 6. Place shims determined in step 4 on ring gear hub of differential case. 7. Install bearing cone on ring gear side of differential case, then drive bearing into place. 8. To determine thickness of shims required on hub of drive pinion side of differential case, subtract thickness of shims installed in step 6 from total differential case endplay as measured in ``Differential Case Assembly'' procedure. To this figure, add .015 inch. 9. Place shims determined in step 8 on hub of drive pinion side of differential case. 10. Install bearing cone on hub of drive pinion side of differential case. 11. Position suitable step plate on ring gear side bearing to protect bearing. 12. Place bearing on drive pinion side hub and drive it into position. 13. Install spreader tool and dial indicator as previously described. Do not spread case more than .015 inch. 14. Assemble differential bearing cups to bearing cones, then install differential assembly into carrier. 15. Tap differential assembly into position in carrier using a soft-faced hammer, then remove spreader tool from case. 16. Install bearing caps in proper position, then torque cap screws to 80---90 ft. lbs. on except model 30 axle or 35---50 ft. lbs on model 30 axle. 17. Measure ring gear and pinion backlash at three equidistant points using a dial indicator. Backlash must measure .004---.009 inch on except model 30 axle or .005---.009 inch on model 30 axle and cannot vary more than .003 inch on except model 30 axle or .002 inch on model 30 axle between points checked. Backlash may be brought within specifications by switching shims from one side of differential case to the other. Move ring gear closer to pinion to correct high backlash, or further away from pinion to correct low backlash. 18. On except model 30 axle having a cover plate without a flat mounting surface, install cover plate, using a new gasket, and torque attaching bolts alternately and evenly to 30---40 ft. lbs. On model 30 axle, torque cover attaching bolts to 15---25 ft. lbs. 19. On units having a cover plate with a flat mounting surface, install cover as follows: a. Clean flat surface of cover plate and carrier mating surface. b. Apply suitable sealant to cover plate surface, ensuring bead of sealant is laid on inside of cover screw holes. c. Install two attaching bolts into cover at 2 o'clock and 8 o'clock positions. d. Position cover on carrier, then install remaining attaching bolts. e. Torque all attaching bolts alternately and evenly to 30---40 ft. lbs. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Adjustments > Assembly of Differential Into Housing > Page 2100 Ring Gear: Adjustments Backlash & Differential Bearing Preload Adjustment FORD REMOVABLE CARRIER 1. Remove adjusting nut locks and loosen differential bearing cap bolts, then torque cap bolts to approximately 20 ft. lbs. Left adjusting nut is on ring gear side of carrier and right adjusting nut is on pinion side. 2. Loosen right nut until it is away from cup and tighten left nut until ring gear is just forced into position with zero backlash, then rotate pinion several revolutions to ensure that no binding is evident. 3. Check right nut to ensure that it is still loose, then install dial indicator. 4. Tighten right nut until it just contacts bearing cup, then set dial indicator to zero and apply pressure to bearings by tightening right nut until indicator reads .008---.012 inch. 5. Turn pinion gear several times in each direction to seat bearings in cups and ensure that no binding is evident, then torque bearing caps to 70---80 ft. lbs. 6. Measure backlash on several teeth around ring gear. 7. If backlash varies by more than .004 inch between any two teeth, loosen one adjusting nut and tighten opposite nut an equal amount to move ring gear away from or toward pinion. Tightening left nut moves ring gear into pinion to decrease backlash while tightening right nut moves ring gear away. When moving adjusting nuts, final movement should always be made in a tightening direction. Assuming left nut had to be loosened one notch, loosen nut two notches, then tighten one notch. 8. Ensure that case spread remains within specifications as previously described. 9. Perform teeth pattern check as described under ``General Axle Service.'' If backlash is correct and gross pattern error results, recheck pinion shim selection. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Dana/Spicer Integral Housing Type Axle Bearing: Service and Repair Dana/Spicer Integral Housing Type Full-Floating Axle 1. Set parking brake and loosen axle shaft bolts. 2. Raise and support rear of vehicle so that axle is parallel with floor. 3. Remove axle shaft bolts. 4. Remove axle shaft and discard gasket. 5. Pry out locking wedge with screwdriver. 6. Raise wheel until weight is removed from wheel bearing. 7. Remove wheel bearing adjustment nut. 8. Remove outer bearing cone and pull wheel assembly from axle. 9. Drive inner bearing cone and seal out of wheel hub with brass drift. 10. Inspect bearings and races and replace if worn or damaged. Drive races from wheel hub with brass drift. 11. Lubricate bearing cone and roller assemblies and place inner assemblies into wheel hub. Install new hub inner seal. 12. Wrap spindle threads with tape, then slide wheel assembly onto axle housing spindle and remove tape. 13. Install outer wheel bearing and start adjuster nut. Lower wheel to ground. 14. While rotating wheel, torque adjusting nut to 120-140 ft. lbs. Back off the nut to obtain 0.001---0.010 inch endplay (1/8-3/8 turn). If nut or locking wedge are damaged or do not allow for proper endplay they should be replaced. 15. Position locking wedge in key way slot, making sure it is not bottomed against the shoulder of adjusting nut. 16. Install axle shaft and new flange gasket, then install retaining bolts and torque locking bolts to 40---50 ft. lbs. 17. Adjust brakes. 18. Remove supports and lower vehicle. Semi-Floating Axle 1. Raise and support vehicle. 2. Remove wheel and brake drum. 3. Remove cover plate and discard gasket. 4. Remove differential pinion shaft lock screw and the shaft. 5. Remove C-clip from button end of shaft by pushing inward on other end. 6. Pull shaft from axle tube. Do not rotate differential side gears. 7. Remove and discard oil seal from axle tube. 8. Pull bearing from axle tube. 9. Lubricate new bearing and install in axle tube. 10. Lubricate and install new oil seal. 11. Insert shaft into axle tube, making sure splines engage side gears, then install C-clip and pull shaft outward until the clip locks. 12. Install pinion mate shaft, aligning lock pin holes, and pinion gear side washers. 13. Install new lock screw and torque to 8 ft. lbs. on 1980---81 models, or 20---25 ft. lbs. on 1982---87 models. 14. Install cover plate and gasket. Torque bolts to 30---40 ft. lbs. 15. Install wheel and drum assembly. 16. Remove supports and lower vehicle. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Dana/Spicer Integral Housing Type > Page 2106 Axle Bearing: Service and Repair Ford Integral Carrier Type Axle 1. Remove axle shaft as outlined in ``Axle Shaft, Replace''. 2. Insert tool T83T-1226-A for models with 8.8 inch ring gear, or tool T85T-1225-AH for models with 10.25 inch ring gear, and tool T50T-100-A into axle bore so tangs on tool engage bearing outer race. Remove bearing and seal as an assembly. 3. Install new bearing using tool T83T-1225-B on models with 8.8 inch ring gear, or tool T80T-4000-W on models with 10.25 inch ring gear, and new seal using tool T83T-1175-A on models with 8.8 inch ring gear, or tool T80T-4000-Y on models with 10.25 inch ring gear. Pack lips of seal with C1AZ-19590-B or equivalent. 4. Reinstall axle. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Bearing > Component Information > Service and Repair > Dana/Spicer Integral Housing Type > Page 2107 Axle Bearing: Service and Repair Ford Removable Carrier Type Removal, Units w/Ball Bearing 1. Remove wheel assembly. 2. Remove brake drum from flange. 3. Working through hole provided in axle shaft flange, remove nuts that secure wheel bearing retainer. 4. Pull axle shaft out of housing. If bearing is a tight fit in axle housing, use a slide hammer type puller. 5. Remove brake backing plate and secure to frame rail. 6. If the axle shaft bearing is to be replaced, loosen the inner retainer by nicking it deeply with a chisel in several places. The bearing will then slide off easily. 7. Press bearing from axle shaft. 8. Inspect machined surface of axle shaft and housing for rough spots that would affect sealing action of the oil seal. Carefully remove any burrs or rough spots. Installation 1. Press new bearing on shaft until it seats firmly against shoulder on shaft. 2. Press inner bearing retainer on shaft until it seats firmly against bearing. 3. If oil seal is to be replaced, use a hook-type tool to pull it out of housing. Wipe a small amount of oil resistant sealer on outer edge of seal before it is installed. Removal, Units W/Roller Bearing 1. Remove wheel assembly. 2. Remove brake drum from flange. 3. Working through hole provided in axle flange, remove nuts securing wheel bearing retainer. 4. Pull axle shaft carefully from housing to prevent damage to outer seal rubber. Use a slide hammer type puller to remove tapered bearing cup from housing. Remove brake backing plate and secure to frame rail. 5. If the axle shaft bearing or seal is to be replaced, split the inner bearing retainer. 6. Press bearing from axle shaft. 7. Inspect machined surface of axle shaft and housing for rough spots that would affect sealing action of the oil seal. Carefully remove any burrs or rough spots. 8. Install outer retainer plate on axle shaft. Press lubricated seal and bearing onto shaft until firmly seated. Oil seal for rear drum brake equipped vehicles is different than that used on vehicles with rear disc brakes. Seals used with drum brakes have a gray metal colored outer rim, while seals used with disc brakes have a black or orange color. 9. Press new bearing retainer onto shaft until seated. Installation 1. On 1980---84 models, place a new gasket on each side of brake carrier plate, and slide axle shaft into housing. On models with roller bearing, ensure outer seal is fully seated on bearing. 2. Start splines into differential side gear and push shaft in until bearing bottoms in housing. 3. Torque bearing retainer nuts to 20---40 ft. lbs. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Dana/Spicer Integral Housing Type Axle Shaft: Service and Repair Dana/Spicer Integral Housing Type Full-Floating Axle 1. Set parking brake and loosen axle shaft bolts. 2. Raise and support rear of vehicle so that axle is parallel with floor. 3. Remove axle shaft bolts. 4. Remove axle shaft and discard gasket. 5. Pry out locking wedge with screwdriver. 6. Raise wheel until weight is removed from wheel bearing. 7. Remove wheel bearing adjustment nut. 8. Remove outer bearing cone and pull wheel assembly from axle. 9. Drive inner bearing cone and seal out of wheel hub with brass drift. 10. Inspect bearings and races and replace if worn or damaged. Drive races from wheel hub with brass drift. 11. Lubricate bearing cone and roller assemblies and place inner assemblies into wheel hub. Install new hub inner seal. 12. Wrap spindle threads with tape, then slide wheel assembly onto axle housing spindle and remove tape. 13. Install outer wheel bearing and start adjuster nut. Lower wheel to ground. 14. While rotating wheel, torque adjusting nut to 120-140 ft. lbs. Back off the nut to obtain 0.001---0.010 inch endplay (1/8-3/8 turn). If nut or locking wedge are damaged or do not allow for proper endplay they should be replaced. 15. Position locking wedge in key way slot, making sure it is not bottomed against the shoulder of adjusting nut. 16. Install axle shaft and new flange gasket, then install retaining bolts and torque locking bolts to 40---50 ft. lbs. 17. Adjust brakes. 18. Remove supports and lower vehicle. Semi-Floating Axle 1. Raise and support vehicle. 2. Remove wheel and brake drum. 3. Remove cover plate and discard gasket. 4. Remove differential pinion shaft lock screw and the shaft. 5. Remove C-clip from button end of shaft by pushing inward on other end. 6. Pull shaft from axle tube. Do not rotate differential side gears. 7. Remove and discard oil seal from axle tube. 8. Pull bearing from axle tube. 9. Lubricate new bearing and install in axle tube. 10. Lubricate and install new oil seal. 11. Insert shaft into axle tube, making sure splines engage side gears, then install C-clip and pull shaft outward until the clip locks. 12. Install pinion mate shaft, aligning lock pin holes, and pinion gear side washers. 13. Install new lock screw and torque to 8 ft. lbs. on 1980---81 models, or 20---25 ft. lbs. on 1982---87 models. 14. Install cover plate and gasket. Torque bolts to 30---40 ft. lbs. 15. Install wheel and drum assembly. 16. Remove supports and lower vehicle. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Dana/Spicer Integral Housing Type > Page 2113 Axle Shaft: Service and Repair Ford Integral Carrier Type Axle 1. Raise and support vehicle, then remove rear wheel and brake drum. 2. Loosen rear housing cover screws and allow lubricant to drain, then remove cover. 3. Remove differential pinion shaft lock bolt and differential pinion shaft. 4. Move flanged end of axle shaft inward and remove C-lock from end of shaft. 5. Remove axle shaft from housing by pulling outward. 6. Reverse procedure to install. Apply Loctite EOAZ-19554-B to pinion shaft lock bolt threads, then torque lock bolt to 15-30 ft. lbs. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Dana/Spicer Integral Housing Type > Page 2114 Axle Shaft: Service and Repair Ford Removable Carrier Type Removal, Units w/Ball Bearing 1. Remove wheel assembly. 2. Remove brake drum from flange. 3. Working through hole provided in axle shaft flange, remove nuts that secure wheel bearing retainer. 4. Pull axle shaft out of housing. If bearing is a tight fit in axle housing, use a slide hammer type puller. 5. Remove brake backing plate and secure to frame rail. 6. If the axle shaft bearing is to be replaced, loosen the inner retainer by nicking it deeply with a chisel in several places. The bearing will then slide off easily. 7. Press bearing from axle shaft. 8. Inspect machined surface of axle shaft and housing for rough spots that would affect sealing action of the oil seal. Carefully remove any burrs or rough spots. Installation 1. Press new bearing on shaft until it seats firmly against shoulder on shaft. 2. Press inner bearing retainer on shaft until it seats firmly against bearing. 3. If oil seal is to be replaced, use a hook-type tool to pull it out of housing. Wipe a small amount of oil resistant sealer on outer edge of seal before it is installed. Removal, Units W/Roller Bearing 1. Remove wheel assembly. 2. Remove brake drum from flange. 3. Working through hole provided in axle flange, remove nuts securing wheel bearing retainer. 4. Pull axle shaft carefully from housing to prevent damage to outer seal rubber. Use a slide hammer type puller to remove tapered bearing cup from housing. Remove brake backing plate and secure to frame rail. 5. If the axle shaft bearing or seal is to be replaced, split the inner bearing retainer. 6. Press bearing from axle shaft. 7. Inspect machined surface of axle shaft and housing for rough spots that would affect sealing action of the oil seal. Carefully remove any burrs or rough spots. 8. Install outer retainer plate on axle shaft. Press lubricated seal and bearing onto shaft until firmly seated. Oil seal for rear drum brake equipped vehicles is different than that used on vehicles with rear disc brakes. Seals used with drum brakes have a gray metal colored outer rim, while seals used with disc brakes have a black or orange color. 9. Press new bearing retainer onto shaft until seated. Installation 1. On 1980---84 models, place a new gasket on each side of brake carrier plate, and slide axle shaft into housing. On models with roller bearing, ensure outer seal is fully seated on bearing. 2. Start splines into differential side gear and push shaft in until bearing bottoms in housing. 3. Torque bearing retainer nuts to 20---40 ft. lbs. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Service and Repair Seals and Gaskets: Service and Repair Removal, Units w/Ball Bearing 1. Remove wheel assembly. 2. Remove brake drum from flange. 3. Working through hole provided in axle shaft flange, remove nuts that secure wheel bearing retainer. 4. Pull axle shaft out of housing. If bearing is a tight fit in axle housing, use a slide hammer type puller. 5. Remove brake backing plate and secure to frame rail. 6. If the axle shaft bearing is to be replaced, loosen the inner retainer by nicking it deeply with a chisel in several places. The bearing will then slide off easily. 7. Press bearing from axle shaft. 8. Inspect machined surface of axle shaft and housing for rough spots that would affect sealing action of the oil seal. Carefully remove any burrs or rough spots. Installation 1. Press new bearing on shaft until it seats firmly against shoulder on shaft. 2. Press inner bearing retainer on shaft until it seats firmly against bearing. 3. If oil seal is to be replaced, use a hook-type tool to pull it out of housing. Wipe a small amount of oil resistant sealer on outer edge of seal before it is installed. Removal, Units W/Roller Bearing 1. Remove wheel assembly. 2. Remove brake drum from flange. 3. Working through hole provided in axle flange, remove nuts securing wheel bearing retainer. 4. Pull axle shaft carefully from housing to prevent damage to outer seal rubber. Use a slide hammer type puller to remove tapered bearing cup from housing. Remove brake backing plate and secure to frame rail. 5. If the axle shaft bearing or seal is to be replaced, split the inner bearing retainer. 6. Press bearing from axle shaft. 7. Inspect machined surface of axle shaft and housing for rough spots that would affect sealing action of the oil seal. Carefully remove any burrs or rough spots. 8. Install outer retainer plate on axle shaft. Press lubricated seal and bearing onto shaft until firmly seated. Oil seal for rear drum brake equipped vehicles is different than that used on vehicles with rear disc brakes. Seals used with drum brakes have a gray metal colored outer rim, while seals used with disc brakes have a black or orange color. 9. Press new bearing retainer onto shaft until seated. Installation 1. On 1980---84 models, place a new gasket on each side of brake carrier plate, and slide axle shaft into housing. On models with roller bearing, ensure outer seal is fully seated on bearing. 2. Start splines into differential side gear and push shaft in until bearing bottoms in housing. 3. Torque bearing retainer nuts to 20---40 ft. lbs. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Adjustments Wheel Bearing: Adjustments EXCEPT 4 WHEEL DRIVE MODELS 1. Remove wheel and tire assembly, disc brake caliper and pads, dust cap, locknut, adjusting nut, washer and cotter pin. 2. Tighten wheel adjusting nut to 22-25 ft. lbs. while rotating disc brake rotor in opposite direction. 3. Back off wheel retention nut 1/8 turn and install retainer and cotter pin without any additional movement of nut. 4. Reinstall dust cap, caliper, pads and tire and wheel assembly. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Adjustments > Page 2121 Wheel Bearing: Service and Repair EXC. 4 WHEEL DRIVE MODELS 1. Raise and support front of vehicle and remove front wheels. 2. Remove brake caliper and position aside, leaving brake lines attached. Do not allow weight of caliper to hang on brake lines. 3. Remove grease cap, cotter pin, locknut, adjusting nut and washer, then the outer bearing cone and roller. 4. Remove hub and rotor and discard grease retainer. 5. Remove inner bearing and roller. 6. Reverse procedure to install. Adjust bearings as described under ``Wheel Bearings, Adjust''. 4 WHEEL DRIVE MODELS 1. Raise and support front of vehicle and remove front wheels. 2. On models equipped with locking hubs, remove hubs as described in ``Front Wheel Drive Section''. 3. On 1980---81 models, remove front hub grease cap. 4. On 1980---81 models, remove driving hub snap ring, then the splined driving hub and pressure spring. 5. On all models, remove wheel bearing locknut, lock ring and adjusting nut, then the hub and disc assembly. The outer bearing and roller assembly will slide out when the hub is removed. 6. Remove inner bearing and grease seal from wheel hub using a suitable driving tool on 1980---81 models or a puller on 1982---87 models. 7. Reverse procedure to install. Adjust bearings as described under ``Wheel Bearings, Adjust''. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Propeller Shaft <--> [Drive/Propeller Shaft] > Component Information > Technical Service Bulletins > Customer Interest for Propeller Shaft: > 872218 > Nov > 87 > Driveline - Clunk/Grunt Noise On Start Up Propeller Shaft: Customer Interest Driveline - Clunk/Grunt Noise On Start Up Article No. 87-22-18 ^ DRIVELINE - "CLUNK" OR "GRUNT" NOISE FROM DRIVELINE DURING STARTING AND STOPPING ^ NOISE - "CLUNK" OR "GRUNT" FROM DRIVELINE DURING STARTING AND STOPPING LIGHT TRUCK: 1978-87 E-250/350 1981-87 F-150/350, E-150 1983-87 RANGER 1986-87 AEROSTAR This article is being republished in its entirety to clarify the slip yoke application chart. ISSUE: A "clunk" or "grunt" noise from the vehicle driveline during start-up and stopping drive modes may be caused by engine torque preventing the slip yoke from sliding smoothly on the transmission output shaft splines. During the same drive modes, rear suspension wrap-up overcomes slip yoke-to-output shaft friction causing sudden slip yoke/driveshaft movement, which results in a "clunk" or "grunt" noise. The affected vehicles are 1978-87 E-250/350 with a C6 transmission; 1981-87 F-150/350 (4x2) with a C6, NPG 435, AOD, TOD, or T18 transmission; 1981-87 E-150 with a C6 or AOD transmission; 1985-86 F- 150/250 (4x4); 1983-87 Ranger (4x2) and 1986-87 Aerostar. ACTION: To correct this, install a new design slip yoke with nickel-plated splines to allow for smooth slip yoke movement. Refer to the appropriate Shop Manual, Section 15-60 for slip yoke removal and installation procedures. Also, refer to the slip yoke application chart below for the correct service part number. PART NUMBER PART NAME CLASS E6TZ-4841-D Slip Yoke C E6TZ-4841-E Slip Yoke C E6TZ-4841-F Slip Yoke C E4TZ-4841-G Slip Yoke B E1TZ-4841-D Slip Yoke B D5UZ-4841-C Slip Yoke B OTHER APPLICABLE ARTICLES: Supersedes 86-21-14, 87-17-11 WARRANTY STATUS: Eligible Under Powertrain Coverage OPERATION: SP872218A TIME: 0.6 Hr. DLR. CODING: Basic Part No. 4841 - Code: 41 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Propeller Shaft <--> [Drive/Propeller Shaft] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Propeller Shaft: > 872218 > Nov > 87 > Driveline - Clunk/Grunt Noise On Start Up Propeller Shaft: All Technical Service Bulletins Driveline - Clunk/Grunt Noise On Start Up Article No. 87-22-18 ^ DRIVELINE - "CLUNK" OR "GRUNT" NOISE FROM DRIVELINE DURING STARTING AND STOPPING ^ NOISE - "CLUNK" OR "GRUNT" FROM DRIVELINE DURING STARTING AND STOPPING LIGHT TRUCK: 1978-87 E-250/350 1981-87 F-150/350, E-150 1983-87 RANGER 1986-87 AEROSTAR This article is being republished in its entirety to clarify the slip yoke application chart. ISSUE: A "clunk" or "grunt" noise from the vehicle driveline during start-up and stopping drive modes may be caused by engine torque preventing the slip yoke from sliding smoothly on the transmission output shaft splines. During the same drive modes, rear suspension wrap-up overcomes slip yoke-to-output shaft friction causing sudden slip yoke/driveshaft movement, which results in a "clunk" or "grunt" noise. The affected vehicles are 1978-87 E-250/350 with a C6 transmission; 1981-87 F-150/350 (4x2) with a C6, NPG 435, AOD, TOD, or T18 transmission; 1981-87 E-150 with a C6 or AOD transmission; 1985-86 F- 150/250 (4x4); 1983-87 Ranger (4x2) and 1986-87 Aerostar. ACTION: To correct this, install a new design slip yoke with nickel-plated splines to allow for smooth slip yoke movement. Refer to the appropriate Shop Manual, Section 15-60 for slip yoke removal and installation procedures. Also, refer to the slip yoke application chart below for the correct service part number. PART NUMBER PART NAME CLASS E6TZ-4841-D Slip Yoke C E6TZ-4841-E Slip Yoke C E6TZ-4841-F Slip Yoke C E4TZ-4841-G Slip Yoke B E1TZ-4841-D Slip Yoke B D5UZ-4841-C Slip Yoke B OTHER APPLICABLE ARTICLES: Supersedes 86-21-14, 87-17-11 WARRANTY STATUS: Eligible Under Powertrain Coverage OPERATION: SP872218A TIME: 0.6 Hr. DLR. CODING: Basic Part No. 4841 - Code: 41 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > Customer Interest for Slip Yoke: > 872218 > Nov > 87 > Driveline Clunk/Grunt Noise On Start Up Slip Yoke: Customer Interest Driveline - Clunk/Grunt Noise On Start Up Article No. 87-22-18 ^ DRIVELINE - "CLUNK" OR "GRUNT" NOISE FROM DRIVELINE DURING STARTING AND STOPPING ^ NOISE - "CLUNK" OR "GRUNT" FROM DRIVELINE DURING STARTING AND STOPPING LIGHT TRUCK: 1978-87 E-250/350 1981-87 F-150/350, E-150 1983-87 RANGER 1986-87 AEROSTAR This article is being republished in its entirety to clarify the slip yoke application chart. ISSUE: A "clunk" or "grunt" noise from the vehicle driveline during start-up and stopping drive modes may be caused by engine torque preventing the slip yoke from sliding smoothly on the transmission output shaft splines. During the same drive modes, rear suspension wrap-up overcomes slip yoke-to-output shaft friction causing sudden slip yoke/driveshaft movement, which results in a "clunk" or "grunt" noise. The affected vehicles are 1978-87 E-250/350 with a C6 transmission; 1981-87 F-150/350 (4x2) with a C6, NPG 435, AOD, TOD, or T18 transmission; 1981-87 E-150 with a C6 or AOD transmission; 1985-86 F- 150/250 (4x4); 1983-87 Ranger (4x2) and 1986-87 Aerostar. ACTION: To correct this, install a new design slip yoke with nickel-plated splines to allow for smooth slip yoke movement. Refer to the appropriate Shop Manual, Section 15-60 for slip yoke removal and installation procedures. Also, refer to the slip yoke application chart below for the correct service part number. PART NUMBER PART NAME CLASS E6TZ-4841-D Slip Yoke C E6TZ-4841-E Slip Yoke C E6TZ-4841-F Slip Yoke C E4TZ-4841-G Slip Yoke B E1TZ-4841-D Slip Yoke B D5UZ-4841-C Slip Yoke B OTHER APPLICABLE ARTICLES: Supersedes 86-21-14, 87-17-11 WARRANTY STATUS: Eligible Under Powertrain Coverage OPERATION: SP872218A TIME: 0.6 Hr. DLR. CODING: Basic Part No. 4841 - Code: 41 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > Customer Interest for Slip Yoke: > 831623 > Aug > 83 > Driveshaft Slip Yoke - Driveline Clunk Slip Yoke: Customer Interest Driveshaft Slip Yoke - Driveline Clunk Article No. 83-16-23 NOISE - DRIVELINE CLUNK - AUTOMATIC TRANSMISSION/ONE-PIECE DRIVESHAFT LIGHT TRUCKS 1981-83 E & F100-350 A driveline clunk/grunt noise at start-up and stop driving modes on some 1981-1983 light truck vehicles, equipped with one-piece driveshafts and C4, C5, C6 or AOD automatic transmissions, may be caused by slip yoke bind-up. To service this condition, perform the following procedure: ^ Raise the vehicle on a hoist. ^ Remove the driveshaft assembly. NOTE: Mark the driveshaft in relation to the companion flange as it must be reinstalled in its original position. ^ Inspect extension housing seal and replace as required. ^ Remove (and discard) slip yoke from the driveshaft. ^ Using the following chart, install a replacement slip yoke (blind spline) on the driveshaft. Grease the slip yoke 360~ with ESA-M1C75-B multi-purpose long life lubricant. NOTE: Complete lubricant coverage (no dry spots on spline) is necessary to ensure proper break-in and prevention of recurring clunk. ^ Reinstall driveshaft and torque U-bolts 8-15 ft.lbs. ^ Road test. NOTE: Vehicle should reach normal operating temperature during road test in order to properly check transmission oil level. Add transmission fluid, as required, per Shop Manual Section 17-01. CONSULT THE APPROPRIATE MODEL YEAR LIGHT TRUCK SHOP MANUAL WHEN PERFORMING THE ABOVE OPERATIONS. PART NUMBER PART NAME CLASS E1TZ-4841-B Slip Yoke C4, 5, AOD 28T BM E1TZ-4841-C Slip Yoke C6 BM (except E250/350) 31T D5UZ-4841-A Slip Yoke C6 (E250/350) 31T C C1AZ-19590-B Lubricant - ESA-M1C75-B AG OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION/TIME: Refer to the Labor Time Standards Manual for applicable operation and time. DLR. CODING: Basic Part No. 4841 Code: 41 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Slip Yoke: > 872218 > Nov > 87 > Driveline - Clunk/Grunt Noise On Start Up Slip Yoke: All Technical Service Bulletins Driveline - Clunk/Grunt Noise On Start Up Article No. 87-22-18 ^ DRIVELINE - "CLUNK" OR "GRUNT" NOISE FROM DRIVELINE DURING STARTING AND STOPPING ^ NOISE - "CLUNK" OR "GRUNT" FROM DRIVELINE DURING STARTING AND STOPPING LIGHT TRUCK: 1978-87 E-250/350 1981-87 F-150/350, E-150 1983-87 RANGER 1986-87 AEROSTAR This article is being republished in its entirety to clarify the slip yoke application chart. ISSUE: A "clunk" or "grunt" noise from the vehicle driveline during start-up and stopping drive modes may be caused by engine torque preventing the slip yoke from sliding smoothly on the transmission output shaft splines. During the same drive modes, rear suspension wrap-up overcomes slip yoke-to-output shaft friction causing sudden slip yoke/driveshaft movement, which results in a "clunk" or "grunt" noise. The affected vehicles are 1978-87 E-250/350 with a C6 transmission; 1981-87 F-150/350 (4x2) with a C6, NPG 435, AOD, TOD, or T18 transmission; 1981-87 E-150 with a C6 or AOD transmission; 1985-86 F- 150/250 (4x4); 1983-87 Ranger (4x2) and 1986-87 Aerostar. ACTION: To correct this, install a new design slip yoke with nickel-plated splines to allow for smooth slip yoke movement. Refer to the appropriate Shop Manual, Section 15-60 for slip yoke removal and installation procedures. Also, refer to the slip yoke application chart below for the correct service part number. PART NUMBER PART NAME CLASS E6TZ-4841-D Slip Yoke C E6TZ-4841-E Slip Yoke C E6TZ-4841-F Slip Yoke C E4TZ-4841-G Slip Yoke B E1TZ-4841-D Slip Yoke B D5UZ-4841-C Slip Yoke B OTHER APPLICABLE ARTICLES: Supersedes 86-21-14, 87-17-11 WARRANTY STATUS: Eligible Under Powertrain Coverage OPERATION: SP872218A TIME: 0.6 Hr. DLR. CODING: Basic Part No. 4841 - Code: 41 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Slip Yoke: > 831623 > Aug > 83 > Driveshaft Slip Yoke - Driveline Clunk Slip Yoke: All Technical Service Bulletins Driveshaft Slip Yoke - Driveline Clunk Article No. 83-16-23 NOISE - DRIVELINE CLUNK - AUTOMATIC TRANSMISSION/ONE-PIECE DRIVESHAFT LIGHT TRUCKS 1981-83 E & F100-350 A driveline clunk/grunt noise at start-up and stop driving modes on some 1981-1983 light truck vehicles, equipped with one-piece driveshafts and C4, C5, C6 or AOD automatic transmissions, may be caused by slip yoke bind-up. To service this condition, perform the following procedure: ^ Raise the vehicle on a hoist. ^ Remove the driveshaft assembly. NOTE: Mark the driveshaft in relation to the companion flange as it must be reinstalled in its original position. ^ Inspect extension housing seal and replace as required. ^ Remove (and discard) slip yoke from the driveshaft. ^ Using the following chart, install a replacement slip yoke (blind spline) on the driveshaft. Grease the slip yoke 360~ with ESA-M1C75-B multi-purpose long life lubricant. NOTE: Complete lubricant coverage (no dry spots on spline) is necessary to ensure proper break-in and prevention of recurring clunk. ^ Reinstall driveshaft and torque U-bolts 8-15 ft.lbs. ^ Road test. NOTE: Vehicle should reach normal operating temperature during road test in order to properly check transmission oil level. Add transmission fluid, as required, per Shop Manual Section 17-01. CONSULT THE APPROPRIATE MODEL YEAR LIGHT TRUCK SHOP MANUAL WHEN PERFORMING THE ABOVE OPERATIONS. PART NUMBER PART NAME CLASS E1TZ-4841-B Slip Yoke C4, 5, AOD 28T BM E1TZ-4841-C Slip Yoke C6 BM (except E250/350) 31T D5UZ-4841-A Slip Yoke C6 (E250/350) 31T C C1AZ-19590-B Lubricant - ESA-M1C75-B AG OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION/TIME: Refer to the Labor Time Standards Manual for applicable operation and time. DLR. CODING: Basic Part No. 4841 Code: 41 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Description and Operation Universal Joint: Description and Operation Fig. 3 Cross & roller type universal joints Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Description and Operation > Page 2160 Fig. 4 Cross & roller type universal joints & propeller shaft Figs. 3 and 4 illustrate typical examples of universal joints of this type. They all operate on the same principle and similar service and replacement procedures may be applied to all. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Servicing Using Universal Joint Replacement Tool Universal Joint: Service and Repair Servicing Using Universal Joint Replacement Tool Fig. 7 Removing bearing caps using tool & adapter Fig. 8 Removing bearing cap by holding cap in vise & striking center yoke with hammer Disassembly 1. Place driveshaft in a vise using care to avoid damaging it. 2. Remove bearing retaining snap rings. Some universal joints use injected nylon retainers in place of snap rings. During servicing, the snap rings supplied with the replacement universal joint assembly must be used. 3. Position tool on shaft and press bearing out of yoke, Fig. 7. If bearing cannot be pressed all the way out, remove it using vise grips or channel lock pliers or position driveshaft as shown and strike center yoke with hammer, Fig. 8. Mark yoke and shaft to make sure they will be reassembled in their same relative positions. 4. Reposition tool so that it presses on the spider in order to press other bearing from opposite side of flange. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Servicing Using Universal Joint Replacement Tool > Page 2163 5. If used, remove flange from spider. Assembly 1. Start new bearing into yoke, then position spider into yoke and press bearing until it is 1/4 inch below surface. 2. Remove tool and install a new snap ring. 3. Start new bearing in opposite side of yoke, then install tool and press on bearing until opposite bearing contacts snap ring. 4. Remove tool and install remaining snap ring. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Servicing Using Universal Joint Replacement Tool > Page 2164 Universal Joint: Service and Repair Servicing Without Universal Joint Replacement Tool Fig. 5 Removing bearings from yoke using a small socket as a driver & large socket as a receiver Disassembly 1. Remove snap rings (or retainer plates) that retain bearings in yoke and drive shaft. 2. Place U-joint in a vise. 3. Select a wrench socket with an outside diameter slightly smaller than the U-joint bearings. Select another wrench socket with an inside diameter slightly larger than the U-joint bearings. 4. Place the sockets at opposite bearings in the yoke so that the smaller socket becomes a bearing pusher and the larger socket becomes a bearing receiver when the vise jaws come together, Fig. 5. Close vise jaws until both bearings are free of yoke and remove bearings from the cross or spider. 5. If bearings will not come all the way out, close vise until bearing in receiver socket protrudes from yoke as much as possible without using excessive force. Then remove from vise and place that portion of bearing which protrudes from yoke between vise jaws. Tighten vise to hold bearing and drive yoke off with a soft hammer. 6. To remove opposite bearing from yoke, replace in vise with pusher socket on exposed cross journal with receiver socket over bearing cup. Then tighten vise jaws to press bearing back through yoke into receiving socket. 7. Remove yoke from drive shaft and again place protruding portion of bearing between vise jaws. Then tighten vise to hold bearing while driving yoke off bearing with soft hammer. 8. Turn spider or cross 1/4 turn and use the same procedure to press bearings out of drive shaft. Fig. 6 Installing bearings into driveshaft yoke Assembly 1. If old parts are to be reassembled, pack bearing cups with universal joint grease. Do not fill cups completely or use excessive amounts as Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint, Drive/Propeller Shaft > Component Information > Service and Repair > Servicing Using Universal Joint Replacement Tool > Page 2165 over-lubrication may damage seals during reassembly. Use new seals. 2. If new parts are being installed, check new bearings for adequate grease before assembling. 3. With the pusher (smaller) socket, press one bearing part way into drive shaft. Position spider into the partially installed bearing. Place second bearing into drive shaft. Fasten drive shaft in vise so that bearings are in contact with faces of vise jaws, Fig. 6. Some spiders are provided with locating lugs which must face toward drive shaft when installed. 4. Press bearings all the way into position and install snap rings or retainer plates. 5. Install bearings in yoke in same manner. When installation is completed, check U-joint for binding or roughness. If free movement is impeded, correct the condition before installation in vehicle. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications Flywheel: Specifications Flywheel To Crankshaft Bolts 75-85 ft.lb Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component Information > Technical Service Bulletins > Customer Interest for Case: > 83625 > Mar > 83 > M/T Vent - T19, Oil Leaks From Breather Vent Case: Customer Interest M/T Vent - T19, Oil Leaks From Breather Vent Article No. 83-6-25 TRANSMISSION - MANUAL - WARNER T19 - OIL LEAKS OUT VENT - VEHICLES OVER 8500 GVW LIGHT TRUCKS 1983 F-250/350, 1982-83 E-350 STRIPPED CHASSIS (WALK-IN VAN) To prevent transmission gear lubricant from spouting out the primary breather vent of vehicles equipped with Warner Gear T19 4-Speed manual transmission, relocate the vent. Referring to Section 16-24, pages 16-24-1, 16-24-3, and 16-24-10, remove the gear shift lever assembly, boot, floor pan cover, weather pad, and gear shift housing from the transmission assembly. - Cover the transmission with a suitable cover (cloth, paper, etc.) to prevent accidental contamination of the transmission gear lubricant. - Unscrew the cap retaining the shift lever assembly in the top of the gear shift housing and remove the shift lever assembly from the housing. FIGURE 28 - Wipe all the grease off the shift lever lower ball and from the shift lever ball seat of the shift housing (see Sections A and B of Figure 28). - Remove and clean all traces of gasket material (RTV) from mounting surfaces of the shift housing and transmission case. Remove all sealer from cover bolts. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component Information > Technical Service Bulletins > Customer Interest for Case: > 83625 > Mar > 83 > M/T Vent - T19, Oil Leaks From Breather Vent > Page 2178 FIGURE 27 - Remove the primary breather vent from the rear top of the shift housing (Figure 27) and press plug, part number 353096-S into the old breather hole. - Referring to Figure 27, locate and drill a 3/8 inch diameter hole, 1-1/4 inch forward and 3/4 inch inboard of the centerline of the left rear shift housing attaching bolt hole. - Press a new breather assembly, part number 01A-7034, into the new 3/8 inch diameter hole in the shift housing. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component Information > Technical Service Bulletins > Customer Interest for Case: > 83625 > Mar > 83 > M/T Vent - T19, Oil Leaks From Breather Vent > Page 2179 FIGURE 28 - Apply a light coating of ESA-M1C75B lubricant to the shift lever lower ball and to the lever ball seat in the shift housing (see Sections A and B of Figure 28). - Apply a 1/8 bead of RTV gasket compound, part number ESB-M4G195A, to the center section and inboard of each bolt hole of the mounting flange (see Section B of Figure 28) of the shift housing. - Apply ESG-M4G194A Thread Sealer to the threads of the six shift housing-to-transmission attaching bolt and lockwasher assemblies and secure the shift housing to transmission case. Tighten all bolts to 25-35 lbs.ft. torque. Position the shift lever assembly to the shift housing and install as shown in Section A of Figure 28. Torque the retaining cap to 8-15 lbs.ft. until the gasket is clamped securely. - Connect the back-up light wire to the back-up light switch on shift housing. - Install weather pad, floor pan cover, and floor mat or carpet as outlined in Section 16-24 of 1983 Light Truck Shop Manual. - Check gear lubricant level in the transmission, add additional ESP-M2C83-C gear lubricant if necessary to fill plug opening. PART NUMBER PART NAME CLASS 01A-7034 Vent C 353096-S Plug S C1AZ-19590-B Lubricant AG D6AZ-19562-A RTV Gasket A D8AZ-19554-A Thread Sealer AM D8DZ-19C547-A Lubricant BG OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component Information > Technical Service Bulletins > Customer Interest for Case: > 83625 > Mar > 83 > M/T Vent - T19, Oil Leaks From Breather Vent > Page 2180 OPERATION: M TIME: "Actual Time" as defined in the Warranty and Policy Manual. DLR. CODING: Basic Part No. 7034 Code: 77 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 83625 > Mar > 83 > M/T Vent - T19, Oil Leaks From Breather Vent Case: All Technical Service Bulletins M/T Vent - T19, Oil Leaks From Breather Vent Article No. 83-6-25 TRANSMISSION - MANUAL - WARNER T19 - OIL LEAKS OUT VENT - VEHICLES OVER 8500 GVW LIGHT TRUCKS 1983 F-250/350, 1982-83 E-350 STRIPPED CHASSIS (WALK-IN VAN) To prevent transmission gear lubricant from spouting out the primary breather vent of vehicles equipped with Warner Gear T19 4-Speed manual transmission, relocate the vent. Referring to Section 16-24, pages 16-24-1, 16-24-3, and 16-24-10, remove the gear shift lever assembly, boot, floor pan cover, weather pad, and gear shift housing from the transmission assembly. - Cover the transmission with a suitable cover (cloth, paper, etc.) to prevent accidental contamination of the transmission gear lubricant. - Unscrew the cap retaining the shift lever assembly in the top of the gear shift housing and remove the shift lever assembly from the housing. FIGURE 28 - Wipe all the grease off the shift lever lower ball and from the shift lever ball seat of the shift housing (see Sections A and B of Figure 28). - Remove and clean all traces of gasket material (RTV) from mounting surfaces of the shift housing and transmission case. Remove all sealer from cover bolts. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 83625 > Mar > 83 > M/T Vent - T19, Oil Leaks From Breather Vent > Page 2186 FIGURE 27 - Remove the primary breather vent from the rear top of the shift housing (Figure 27) and press plug, part number 353096-S into the old breather hole. - Referring to Figure 27, locate and drill a 3/8 inch diameter hole, 1-1/4 inch forward and 3/4 inch inboard of the centerline of the left rear shift housing attaching bolt hole. - Press a new breather assembly, part number 01A-7034, into the new 3/8 inch diameter hole in the shift housing. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 83625 > Mar > 83 > M/T Vent - T19, Oil Leaks From Breather Vent > Page 2187 FIGURE 28 - Apply a light coating of ESA-M1C75B lubricant to the shift lever lower ball and to the lever ball seat in the shift housing (see Sections A and B of Figure 28). - Apply a 1/8 bead of RTV gasket compound, part number ESB-M4G195A, to the center section and inboard of each bolt hole of the mounting flange (see Section B of Figure 28) of the shift housing. - Apply ESG-M4G194A Thread Sealer to the threads of the six shift housing-to-transmission attaching bolt and lockwasher assemblies and secure the shift housing to transmission case. Tighten all bolts to 25-35 lbs.ft. torque. Position the shift lever assembly to the shift housing and install as shown in Section A of Figure 28. Torque the retaining cap to 8-15 lbs.ft. until the gasket is clamped securely. - Connect the back-up light wire to the back-up light switch on shift housing. - Install weather pad, floor pan cover, and floor mat or carpet as outlined in Section 16-24 of 1983 Light Truck Shop Manual. - Check gear lubricant level in the transmission, add additional ESP-M2C83-C gear lubricant if necessary to fill plug opening. PART NUMBER PART NAME CLASS 01A-7034 Vent C 353096-S Plug S C1AZ-19590-B Lubricant AG D6AZ-19562-A RTV Gasket A D8AZ-19554-A Thread Sealer AM D8DZ-19C547-A Lubricant BG OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 83625 > Mar > 83 > M/T Vent - T19, Oil Leaks From Breather Vent > Page 2188 OPERATION: M TIME: "Actual Time" as defined in the Warranty and Policy Manual. DLR. CODING: Basic Part No. 7034 Code: 77 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Drivetrain - Lubricant Usage Fluid - M/T: Technical Service Bulletins Drivetrain - Lubricant Usage Article No. 89-8-16 ^ DRIVETRAIN - LUBRICATION USAGE ^ TRANSMISSION - MANUAL - LUBRICATION USAGE LIGHT TRUCK: 1980-89 BRONCO, ECONOLINE, F-150, F-250, F-350 1983-89 RANGER 1984-89 BRONCO II 1986-89 AEROSTAR ISSUE: A quick reference manual transmission fluid usage chart and a quick reference drivetrain lubrication usage chart for light trucks has been put together to assist technicians in the event service is required. FIGURE 1 FIGURE 2 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Drivetrain - Lubricant Usage > Page 2193 ACTION: Refer to the transmission fluid application chart in Figure 1 for the correct fluid usage. Refer to the drivetrain lubrication application chart in Figure 2 for the correct lubricant usage. PART NUMBER PART NAME CLASS D8DZ-19C547-A Standard Transmission BG Lubricant - 5 gallons C1AZ-19590-BA Long Life Lubricant B (molybdenum disulfide) - 14.5 ounces DOAZ-19584-AA Multi-Purpose Grease - 4 ounce B tube D7AZ-19584-AA Multi-Purpose Grease - 15 B ounce aerosol can XT-2-QDX Transmission Fluid (Mercon) - V quart can (pkg. of 12) C6AZ-19580-E Gear Oil (Dana axle) - 1 gallon AG C8AZ-19B546-A Additive Friction Modifier - 4 AM ounce bottle D7AZ-19590-A Disc Brake Caliper Slide AM Grease - 4 ounce tube E8TZ-19590-A Grease - 14.5 ounces B E1TZ-19590-A Automatic Hublock Grease - 5 B ounce tube E5RY-19C547-A Merkur Synthetic Manual B Transmission Fluid OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 5970 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Drivetrain - Lubricant Usage > Page 2194 Fluid - M/T: Technical Service Bulletins A/T, M/T - New `Mercon' Transmission Fluid TRANSMISSION - AUTOMATIC/MANUAL - Article No. NEW FLUID AND USAGE CHART 87-18-14 FORD: 1986 And Prior LTD 1988 And Prior ESCORT, TEMPO, MUSTANG, TAURUS, THUNDERBIRD, FORD LINCOLN-MERCURY: 1986 And Prior CAPRI, MARQUIS 1987 And Prior LYNX 1988 And Prior TOPAZ, SABLE, COUGAR, MERCURY, MARK VII, CONTINENTAL, LINCOLN TOWN CAR MERKUR: 1985-88 XR4Ti 1988 SCORPIO LIGHT TRUCK: 1988 And Prior E SERIES, F SERIES, BRONCO, RANGER, BRONCO II, AEROSTAR ISSUE: A new Transmission Fluid, MERCON (Ford Specification "MERCON") (XT-2- QDX, Quart), (XT-2-DDX, 55 Gallon Drum) is available for service. Use of the Motorcraft "MERCON" transmission fluid, where specified, will improve cold weather shift effort and synchronized operation. ACTION: The chart on page 44 of this TSB gives transmission fluid applications for automatic transmissions and certain manual transmissions for Ford, Lincoln-Mercury, and Merkur vehicles. NOTE: The use of MERCON is NOT RECOMMENDED for power steering systems. The manual transmission lubricant for the 1985 Merkur XR4Ti is a semi-synthetic oil. When adding oil to the transmission, use only E5RY-19C547-A (Ford Specification ESD-M2C175-A) or equivalent. PART NUMBER PART NAME CLASS XT-2-QDX MERCON - Quart V Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Drivetrain - Lubricant Usage > Page 2195 XT-2-DDX MERCON - 55 Gallon V Drum E5RY-19C547-A Semi-Synthetic Oil B OTHER APPLICABLE ARTICLES: 82-9-9 Supersedes 85-1-15, 85-6-7 WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Page 2196 Fluid - M/T: Specifications TYPE 80W EP CAPACITY, Refill: 3-speed 3.5 pt (US) 4-speed ex. OD 7.0 pt (US) W/OD 4.5 pt (US) Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Technical Service Bulletins > Customer Interest: > 831917 > Sep > 83 > Shift Lever Knob - Pulls Off Shifter M/T: Customer Interest Shift Lever Knob - Pulls Off Article No. 83-19-17 TRANSMISSION/TRANSFER CASES - SHIFT KNOB - PULLS OFF FLOOR SHIFT LEVER LIGHT TRUCKS 1982-84 ALL MODEL LIGHT TRUCKS Figure 17 Shift lever knob "pull-off" may be due to knob damage during installation or lever knurling which is out of specification. The following procedure is to identify the cause and to service the condition (See Figure 17). Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Technical Service Bulletins > Customer Interest: > 831917 > Sep > 83 > Shift Lever Knob - Pulls Off > Page 2205 1. Remove the shift ball from the shift lever assembly by removing the plastic shift pattern insert from the shift ball. Knock the ball off the lever with a block of wood and a hammer. 2. Inspect the lower cavity of the shift ball for broken or missing sections. Discard the ball if broken or missing pieces are noted. (Retain the plastic shift pattern insert). 3. On T-19 transmission inspect the knurled end of the shift lever for undersize/oversize knurling by measuring the knurled diameter. The knurled diameter should be between 37/64" and 19/32" in diameter. 4. If the diameter of the knurled section is less than the specified 37/64" minimum, then the shift lever should be replaced with a new one with good knurls. Also install a new shift ball with the new lever. Figure 17 5. If the knurled diameter is within the specified diameter, replace the shift ball (7213) only, using the original shift lever and shift ball insert. NOTE: Before installing the shift ball on the transmission shift lever and, using a machinist file or suitable hand grinder, file or grind a radius Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Technical Service Bulletins > Customer Interest: > 831917 > Sep > 83 > Shift Lever Knob - Pulls Off > Page 2206 or chamfer on the lever and the start of the knurls so as to remove the step from the top end of the lever and (Figure 17, View A) to aid installation. 6. Install the shift lever ball by warming the ball with a heat gun to 140~ - 180~ and tapping the ball onto the shift lever with a 7/16" socket and a rubber hammer or mallet. Tap the ball down to the beginning of the taper below the knurled section as shown in Figure 17, View A. Install the shift pattern insert. NOTE: Tap the shift ball down on the shift lever to the beginning of the tapered shoulder (Figure 17, View A) below the knurled section of the shift lever assembly. PART NUMBER PART NAME CLASS E2TZ-7213-B Shift Ball B E2TZ-7210-D Shift Lever T-18 R E3TZ-7210-N Shift Lever T-19 C E2TZ-7210-C Shift Lever NPG435 B E2TZ-7210-L Shift Lever SROD R E2TZ-7210-E Shift Lever M4OD R E3TZ-7210-A Shift Lever TK 4 spd. C E4TZ-7210-C Shift Lever TK 5 spd.* C E2TZ-7210-B Shift Lever NP208/W1345 C E3TZ-7210-K Shift Lever W-1350 C * - Shift lever assembly includes shift tower. OTHER APPLICABLE ARTICLES: 82-7-17 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION/TIME: Refer to the Labor Time Standards Manual for applicable operation and time. DLR. CODING: Basic Part No. 7213 or 7210 Code: 01 or 16 as applicable. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 831917 > Sep > 83 > Shift Lever Knob - Pulls Off Shifter M/T: All Technical Service Bulletins Shift Lever Knob - Pulls Off Article No. 83-19-17 TRANSMISSION/TRANSFER CASES - SHIFT KNOB - PULLS OFF FLOOR SHIFT LEVER LIGHT TRUCKS 1982-84 ALL MODEL LIGHT TRUCKS Figure 17 Shift lever knob "pull-off" may be due to knob damage during installation or lever knurling which is out of specification. The following procedure is to identify the cause and to service the condition (See Figure 17). Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 831917 > Sep > 83 > Shift Lever Knob - Pulls Off > Page 2212 1. Remove the shift ball from the shift lever assembly by removing the plastic shift pattern insert from the shift ball. Knock the ball off the lever with a block of wood and a hammer. 2. Inspect the lower cavity of the shift ball for broken or missing sections. Discard the ball if broken or missing pieces are noted. (Retain the plastic shift pattern insert). 3. On T-19 transmission inspect the knurled end of the shift lever for undersize/oversize knurling by measuring the knurled diameter. The knurled diameter should be between 37/64" and 19/32" in diameter. 4. If the diameter of the knurled section is less than the specified 37/64" minimum, then the shift lever should be replaced with a new one with good knurls. Also install a new shift ball with the new lever. Figure 17 5. If the knurled diameter is within the specified diameter, replace the shift ball (7213) only, using the original shift lever and shift ball insert. NOTE: Before installing the shift ball on the transmission shift lever and, using a machinist file or suitable hand grinder, file or grind a radius Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 831917 > Sep > 83 > Shift Lever Knob - Pulls Off > Page 2213 or chamfer on the lever and the start of the knurls so as to remove the step from the top end of the lever and (Figure 17, View A) to aid installation. 6. Install the shift lever ball by warming the ball with a heat gun to 140~ - 180~ and tapping the ball onto the shift lever with a 7/16" socket and a rubber hammer or mallet. Tap the ball down to the beginning of the taper below the knurled section as shown in Figure 17, View A. Install the shift pattern insert. NOTE: Tap the shift ball down on the shift lever to the beginning of the tapered shoulder (Figure 17, View A) below the knurled section of the shift lever assembly. PART NUMBER PART NAME CLASS E2TZ-7213-B Shift Ball B E2TZ-7210-D Shift Lever T-18 R E3TZ-7210-N Shift Lever T-19 C E2TZ-7210-C Shift Lever NPG435 B E2TZ-7210-L Shift Lever SROD R E2TZ-7210-E Shift Lever M4OD R E3TZ-7210-A Shift Lever TK 4 spd. C E4TZ-7210-C Shift Lever TK 5 spd.* C E2TZ-7210-B Shift Lever NP208/W1345 C E3TZ-7210-K Shift Lever W-1350 C * - Shift lever assembly includes shift tower. OTHER APPLICABLE ARTICLES: 82-7-17 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION/TIME: Refer to the Labor Time Standards Manual for applicable operation and time. DLR. CODING: Basic Part No. 7213 or 7210 Code: 01 or 16 as applicable. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Shifter M/T: > 841628 > Jul > 84 > Brakes (Rear) Accelerated Wear Wheel Cylinder: All Technical Service Bulletins Brakes (Rear) - Accelerated Wear Articles No. 84-16-28 BRAKE, REAR - ACCELERATED WEAR - VEHICLES WITH 11" DIAMETER REAR BRAKES LIGHT TRUCKS 1975-84 E & F-100/150 & BRONCO This article supersedes TSB article 83-25-18, dated December 13, 1983, to include all 1975-84 E & F-100/150 & Bronco vehicles that have 11" diameter rear brakes. Some E and F-100/150 and Bronco vehicles subjected to extreme duty cycles in urban delivery/service operations may experience accelerated rear brake wear. A service kit(E0UZ-2C178-A) has been released for these vehicles and should be installed in its entirety if the vehicle exhibits any of the following conditions: ^ Side to side imbalance in rear braking effectiveness. ^ Side to side imbalance in rear brake lining wear. ^ Excessive heat ("blued" shoes and/or drums). The service kit consists of replacement front and rear brake linings, rear wheel cylinders and a proportioning valve. These parts must be installed per the appropriate shop manual installation procedure. NOTE: If a misalignment between the drum braking surface and the shoe ledge guides of the brake backing plate is suspected, refer to TSB 82-24 for the appropriate service procedures before installing the service kit (E0UZ-2C178-A). PART NUMBER PART NAME CLASS E0UZ-2C178-A Brake Service Kit C Front/Rear Services OTHER APPLICABLE ARTICLES: 82-24-17 ARTICLE SUPERSEDED: 83-25-18 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP2178A83 TIME: 2.3 Hrs. DLR. CODING: Basic Part No. 2200 Code: 30 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Lubricant Usage Fluid - Transfer Case: Technical Service Bulletins Drivetrain - Lubricant Usage Article No. 89-8-16 ^ DRIVETRAIN - LUBRICATION USAGE ^ TRANSMISSION - MANUAL - LUBRICATION USAGE LIGHT TRUCK: 1980-89 BRONCO, ECONOLINE, F-150, F-250, F-350 1983-89 RANGER 1984-89 BRONCO II 1986-89 AEROSTAR ISSUE: A quick reference manual transmission fluid usage chart and a quick reference drivetrain lubrication usage chart for light trucks has been put together to assist technicians in the event service is required. FIGURE 1 FIGURE 2 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Technical Service Bulletins > Drivetrain - Lubricant Usage > Page 2229 ACTION: Refer to the transmission fluid application chart in Figure 1 for the correct fluid usage. Refer to the drivetrain lubrication application chart in Figure 2 for the correct lubricant usage. PART NUMBER PART NAME CLASS D8DZ-19C547-A Standard Transmission BG Lubricant - 5 gallons C1AZ-19590-BA Long Life Lubricant B (molybdenum disulfide) - 14.5 ounces DOAZ-19584-AA Multi-Purpose Grease - 4 ounce B tube D7AZ-19584-AA Multi-Purpose Grease - 15 B ounce aerosol can XT-2-QDX Transmission Fluid (Mercon) - V quart can (pkg. of 12) C6AZ-19580-E Gear Oil (Dana axle) - 1 gallon AG C8AZ-19B546-A Additive Friction Modifier - 4 AM ounce bottle D7AZ-19590-A Disc Brake Caliper Slide AM Grease - 4 ounce tube E8TZ-19590-A Grease - 14.5 ounces B E1TZ-19590-A Automatic Hublock Grease - 5 B ounce tube E5RY-19C547-A Merkur Synthetic Manual B Transmission Fluid OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 5970 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications Fluid - Transfer Case: Capacity Specifications TYPE MERCON(R) Automatic Transmission Fluid CAPACITY, Refill: NP208 7.0 pt (US) Warner 1345 6.5 pt (US) Warner 1350 Ranger 3.0 pt (US) Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information > Specifications > Capacity Specifications > Page 2232 Fluid - Transfer Case: Fluid Type Specifications BL Self-adjusting Brake Lubricant EC Ethylene Glycol Coolant Mix 50/50 with water to at least -20°F (-29°C) protection EP Extreme Pressure Gear Lubricant Ford Part No. D8DZ-19C547-A FA Automatic Transmission Fluid, Type F GL-5 Gear Oil, API Service GL-5 HBH Hydraulic Brake Fluid, Extra Heavy-Duty HP Hypoid Gear Oil Ford Part No. E0AZ-19580-A HP* Hypoid Gear Oil for Limited-Slip or Traction-Lok Differential LM Lithium Grease, with Polyethylene LS Steering Gear Lubricant MA MERCONAutomatic Transmission Fluid MH Manifold Heat Valve Solvent SG Motor Oil, API Service SG Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Shifter Transfer Case: > 831917 > Sep > 83 > Shift Lever Knob - Pulls Off Shifter Transfer Case: Customer Interest Shift Lever Knob - Pulls Off Article No. 83-19-17 TRANSMISSION/TRANSFER CASES - SHIFT KNOB - PULLS OFF FLOOR SHIFT LEVER LIGHT TRUCKS 1982-84 ALL MODEL LIGHT TRUCKS Figure 17 Shift lever knob "pull-off" may be due to knob damage during installation or lever knurling which is out of specification. The following procedure is to identify the cause and to service the condition (See Figure 17). Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Shifter Transfer Case: > 831917 > Sep > 83 > Shift Lever Knob - Pulls Off > Page 2241 1. Remove the shift ball from the shift lever assembly by removing the plastic shift pattern insert from the shift ball. Knock the ball off the lever with a block of wood and a hammer. 2. Inspect the lower cavity of the shift ball for broken or missing sections. Discard the ball if broken or missing pieces are noted. (Retain the plastic shift pattern insert). 3. On T-19 transmission inspect the knurled end of the shift lever for undersize/oversize knurling by measuring the knurled diameter. The knurled diameter should be between 37/64" and 19/32" in diameter. 4. If the diameter of the knurled section is less than the specified 37/64" minimum, then the shift lever should be replaced with a new one with good knurls. Also install a new shift ball with the new lever. Figure 17 5. If the knurled diameter is within the specified diameter, replace the shift ball (7213) only, using the original shift lever and shift ball insert. NOTE: Before installing the shift ball on the transmission shift lever and, using a machinist file or suitable hand grinder, file or grind a radius Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information > Technical Service Bulletins > Customer Interest for Shifter Transfer Case: > 831917 > Sep > 83 > Shift Lever Knob - Pulls Off > Page 2242 or chamfer on the lever and the start of the knurls so as to remove the step from the top end of the lever and (Figure 17, View A) to aid installation. 6. Install the shift lever ball by warming the ball with a heat gun to 140~ - 180~ and tapping the ball onto the shift lever with a 7/16" socket and a rubber hammer or mallet. Tap the ball down to the beginning of the taper below the knurled section as shown in Figure 17, View A. Install the shift pattern insert. NOTE: Tap the shift ball down on the shift lever to the beginning of the tapered shoulder (Figure 17, View A) below the knurled section of the shift lever assembly. PART NUMBER PART NAME CLASS E2TZ-7213-B Shift Ball B E2TZ-7210-D Shift Lever T-18 R E3TZ-7210-N Shift Lever T-19 C E2TZ-7210-C Shift Lever NPG435 B E2TZ-7210-L Shift Lever SROD R E2TZ-7210-E Shift Lever M4OD R E3TZ-7210-A Shift Lever TK 4 spd. C E4TZ-7210-C Shift Lever TK 5 spd.* C E2TZ-7210-B Shift Lever NP208/W1345 C E3TZ-7210-K Shift Lever W-1350 C * - Shift lever assembly includes shift tower. OTHER APPLICABLE ARTICLES: 82-7-17 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION/TIME: Refer to the Labor Time Standards Manual for applicable operation and time. DLR. CODING: Basic Part No. 7213 or 7210 Code: 01 or 16 as applicable. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter Transfer Case: > 831917 > Sep > 83 > Shift Lever Knob - Pulls Off Shifter Transfer Case: All Technical Service Bulletins Shift Lever Knob - Pulls Off Article No. 83-19-17 TRANSMISSION/TRANSFER CASES - SHIFT KNOB - PULLS OFF FLOOR SHIFT LEVER LIGHT TRUCKS 1982-84 ALL MODEL LIGHT TRUCKS Figure 17 Shift lever knob "pull-off" may be due to knob damage during installation or lever knurling which is out of specification. The following procedure is to identify the cause and to service the condition (See Figure 17). Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter Transfer Case: > 831917 > Sep > 83 > Shift Lever Knob - Pulls Off > Page 2248 1. Remove the shift ball from the shift lever assembly by removing the plastic shift pattern insert from the shift ball. Knock the ball off the lever with a block of wood and a hammer. 2. Inspect the lower cavity of the shift ball for broken or missing sections. Discard the ball if broken or missing pieces are noted. (Retain the plastic shift pattern insert). 3. On T-19 transmission inspect the knurled end of the shift lever for undersize/oversize knurling by measuring the knurled diameter. The knurled diameter should be between 37/64" and 19/32" in diameter. 4. If the diameter of the knurled section is less than the specified 37/64" minimum, then the shift lever should be replaced with a new one with good knurls. Also install a new shift ball with the new lever. Figure 17 5. If the knurled diameter is within the specified diameter, replace the shift ball (7213) only, using the original shift lever and shift ball insert. NOTE: Before installing the shift ball on the transmission shift lever and, using a machinist file or suitable hand grinder, file or grind a radius Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Shifter Transfer Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shifter Transfer Case: > 831917 > Sep > 83 > Shift Lever Knob - Pulls Off > Page 2249 or chamfer on the lever and the start of the knurls so as to remove the step from the top end of the lever and (Figure 17, View A) to aid installation. 6. Install the shift lever ball by warming the ball with a heat gun to 140~ - 180~ and tapping the ball onto the shift lever with a 7/16" socket and a rubber hammer or mallet. Tap the ball down to the beginning of the taper below the knurled section as shown in Figure 17, View A. Install the shift pattern insert. NOTE: Tap the shift ball down on the shift lever to the beginning of the tapered shoulder (Figure 17, View A) below the knurled section of the shift lever assembly. PART NUMBER PART NAME CLASS E2TZ-7213-B Shift Ball B E2TZ-7210-D Shift Lever T-18 R E3TZ-7210-N Shift Lever T-19 C E2TZ-7210-C Shift Lever NPG435 B E2TZ-7210-L Shift Lever SROD R E2TZ-7210-E Shift Lever M4OD R E3TZ-7210-A Shift Lever TK 4 spd. C E4TZ-7210-C Shift Lever TK 5 spd.* C E2TZ-7210-B Shift Lever NP208/W1345 C E3TZ-7210-K Shift Lever W-1350 C * - Shift lever assembly includes shift tower. OTHER APPLICABLE ARTICLES: 82-7-17 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION/TIME: Refer to the Labor Time Standards Manual for applicable operation and time. DLR. CODING: Basic Part No. 7213 or 7210 Code: 01 or 16 as applicable. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair Brake Bleeding: Service and Repair Bleed primary and secondary hydraulic brake systems separately, bleeding longest line first on each system. Do not allow reservoir to run dry during bleeding operation. Never reuse fluid that has been drained from hydraulic system. 1. Loosen master cylinder to hydraulic line nuts and wrap shop cloths around tubing below fitting to absorb escaping brake fluid. 2. Depress brake pedal slowly by hand to floor of cab, forcing air trapped in master cylinder out at fitting. 3. Hold pedal down and tighten fittings, then release brake pedal. Releasing brake pedal before fittings are tightened will allow air to enter the master cylinder. 4. Repeat steps 1 through 3 until air ceases to escape at fittings and brake pedal is firm. 5. Bleed rear brakes as follows: a. Pump pedal several times, then hold pedal down firmly. b. With pedal firmly depressed, open bleeder screw on one rear brake until pedal fades to floor, then close bleeder valve. c. Repeat procedure until a continuous flow of brake fluid is released from bleeder valve. d. Repeat steps 5a through 5c on other rear brake. 6. Bleed front brakes using same procedure as for rear brakes. 7. Fill master cylinder reservoirs to {1/4} inch from top of reservoirs. 8. Centralize the pressure differential control valve, if applicable, as follows: a. Turn ignition switch to ``ACC'' or ``On'' position. b. Push brake pedal down, allowing piston to center itself, turning off warning light. c. Turn ignition switch to ``OFF'' position. 9. Check brake operation and ensure pedal is firm, then road test vehicle. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 86621 > Mar > 86 > Front Disc Brakes - Clunk During Braking Brake Caliper: Customer Interest Front Disc Brakes - Clunk During Braking Article No. 86-6-21 BRAKES - FRONT DISC - CLUNK LIGHT TRUCK 1980-85 E250/350, F250/350 Some 1980-85 250/350 Econoline and F Series vehicles over 6900 GVW are experiencing front disc brake clunk during braking. This concern can be corrected by using new caliper support keys and springs as outlined in the following procedure. 1. Remove the caliper and clean the sliding surfaces with a wire brush. Apply a light coat of ESAM1C172-A (D7AZ-19590-A) lubricant to both surfaces, being careful not to get lubricant on rotors or linings. 2. Check the front wheel bearing end play adjustment. Adjust the front wheel bearings using the Light Truck Shop Manual procedures, Section 11- 10 and 11-12. 3. Discard the old caliper support key and spring and reinstall the caliper using a new service key (D7TZ- 2B487-B) and spring (D7TZ-2B486-B). PART NUMBER PART NAME CLASS D7TZ-2B487-B Support Key A D7TZ-2B486-B Spring A D7AZ-19590-A Lubricant A OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP2487A86 TIME: 0.6 Hr. DLR. CODING: Basic Part No. 2B487 - Code: 33 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 86621 > Mar > 86 > Front Disc Brakes Clunk During Braking Brake Caliper: All Technical Service Bulletins Front Disc Brakes - Clunk During Braking Article No. 86-6-21 BRAKES - FRONT DISC - CLUNK LIGHT TRUCK 1980-85 E250/350, F250/350 Some 1980-85 250/350 Econoline and F Series vehicles over 6900 GVW are experiencing front disc brake clunk during braking. This concern can be corrected by using new caliper support keys and springs as outlined in the following procedure. 1. Remove the caliper and clean the sliding surfaces with a wire brush. Apply a light coat of ESAM1C172-A (D7AZ-19590-A) lubricant to both surfaces, being careful not to get lubricant on rotors or linings. 2. Check the front wheel bearing end play adjustment. Adjust the front wheel bearings using the Light Truck Shop Manual procedures, Section 11- 10 and 11-12. 3. Discard the old caliper support key and spring and reinstall the caliper using a new service key (D7TZ- 2B487-B) and spring (D7TZ-2B486-B). PART NUMBER PART NAME CLASS D7TZ-2B487-B Support Key A D7TZ-2B486-B Spring A D7AZ-19590-A Lubricant A OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP2487A86 TIME: 0.6 Hr. DLR. CODING: Basic Part No. 2B487 - Code: 33 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal Brake Caliper: Service and Repair Caliper Removal Fig. 1 Bottoming caliper piston in cylinder bore 1. Remove a portion of brake fluid from master cylinder disc brake reservoir. 2. Raise and support vehicle and remove wheel and tire assembly. 3. Install eight inch C-clamp on caliper, Fig. 1, and tighten clamp to bottom piston in cylinder bore, then remove clamp. Do not use screwdriver or other edged tool to pry piston from rotor. 4. Remove key retaining screw, then using hammer and drift, drive out caliper support key and spring. 5. Remove caliper by pushing it downward against spindle assembly and rotating upper end upward and out of spindle assembly. 6. Disconnect hydraulic line from caliper. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal > Page 2270 Brake Caliper: Service and Repair Disassembling Caliper Fig. 2 Removing caliper piston Fig. 3 Exploded view of disc brake caliper assembly 1. Remove plug from caliper inlet port and drain fluid from caliper housing. 2. Position caliper on block of wood, Fig. 2. 3. Slowly and carefully apply low pressure air to caliper inlet port until piston pops out. 4. If piston is jammed or cocked and will not pop out, release air pressure and tap sharply on end of piston with soft hammer or plastic or rubber mallet to straighten piston, then apply air pressure again to remove piston. 5. Remove boot from piston and seal from caliper cylinder bore, Fig. 3. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal > Page 2271 Brake Caliper: Service and Repair Assembling Caliper 1. Lubricate piston seal with clean brake fluid and position seal in groove in cylinder bore. 2. Coat outside of piston and both beads of dust boot with clean brake fluid, then insert piston through dust boot until boot is around closed end of piston. 3. Hold piston and dust boot directly above caliper cylinder bore and use fingers to work bead of dust boot into groove near top of cylinder bore. 4. One bead is seated in groove, press straight down on piston until piston bottoms in bore. Ensure piston is not cocked in bore. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Caliper Removal > Page 2272 Brake Caliper: Service and Repair Caliper Installation 1. Position caliper on spindle assembly by pivoting caliper around support upper mounting surface, being careful not to tear or cut boot as boot slips over inner shoe. 2. Using brake adjusting tool or screwdriver, hold upper machined surface of caliper against surface of support assembly and install new caliper support spring and new caliper support key. 3. Using suitable mallet, drive key and spring assembly into position, then install key retaining screw and torque to 14---20 ft. lbs. 4. Connect hydraulic line to caliper. 5. Install wheel and tire assembly and lower vehicle to ground, then fill master cylinder as necessary with suitable brake fluid. 6. Firmly depress brake pedal several times to seat linings on rotor. 7. Perform brake bleeding procedures. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Customer Interest for Brake Pad: > 86813 > Apr > 86 > Front Disc Brakes - Squealing Noise Brake Pad: Customer Interest Front Disc Brakes - Squealing Noise Article No. 86-8-13 BRAKES - FRONT DISC - SQUEAL LIGHT TRUCK 1980-86 E100/350, F100/350, BRONCO If the subject vehicles are experiencing a brake squeal concern, they should be serviced by installing insulator pads. Information in TSB 85-3-10 should not be used, this new service action supersedes the previous article with updated information. The following procedures and precautions should be observed when servicing front brake squeal concerns. ^ Remove the caliper and clean the sliding surfaces with a wire brush. Apply a light coating of ESAM1C172-A(D7AZ-19590-A) lubricant to both surfaces. Be careful not to get lube on rotors or linings. Wipe any excess lube off after assembly. Visually inspect rotors for any obvious damage or scoring. ^ Check the front wheel bearing end play adjustment. Adjust the front wheel bearings using the procedures included in the Light Truck Shop Manual, Sections 11-10 and 11-12. NOTE: The disc brake caliper and pads must be removed from the spindle prior to adjusting the front wheel bearings. ^ Clean lining and rotor surfaces. Remove any uneven glaze buildup on lining and rotor braking surfaces by sanding with medium to fine sandpaper or emery cloth. Uniform rotor sanding can be accomplished by holding the paper against the rotor braking surface while manually turning the rotor. ^ Remove any loose insulator material from the pad backing plates with sandpaper or an appropriate solvent. This procedure applies only to the following models: 1980-86 E100/150, F100/150, Bronco, F250 4x2 under 6900 lbs. GVW (single piston calipers). ^ Install the service insulator (E1TZ-2B321-A) to the backing plate of the OUTBOARD pad and lining assembly (both L.H. and R.H. brake). Bond the insulator to the back side of the brake pad assembly with ESA-M1C140-A1 (D7AZ-19554-C) adhesive. Apply adhesive to the light color side of each insulator. Assure that insulator is centered on backing plate and that directions for applying adhesive are followed. This procedure is for 1980-86 F250 4x2 over 6900 lbs. GVW, F250 4x4, F350, E250/350 (dual piston calipers). ^ Install the service insulator (E1TZ-2B321-B) to the back side of the INBOARD pad and lining assembly (both L.H. and R.H. brake). Bond the insulator to the backing plate and lining assembly using the previously listed procedure. ^ Install the service shim (E6TZ-2B321-A) to the back side of the outboard pad and lining assembly (both L.H. and R.H. brake) by clipping the shim over the straight edge of the backing plate. Be sure the shim is fully seated and centered on the straight edge of the backing plate. NOTE: For dual piston caliper application only. ^ Reinstall caliper to the spindle assembly. NOTE: DO NOT replace linings unless required for wear or additional concerns (Shop Manual, Section 12-24). PART NUMBER PART NAME CLASS E1TZ-2B321-A Insulator BM E1TZ-2B321-B Insulator BM E6TZ-2B321-A Shim B D7AZ-19590-A Lubricant A D7AZ-19554-C Adhesive AM OTHER APPLICABLE ARTICLES: Supersedes 85-3-10 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP2321A86A - 1980-85 TIME: 1.1 Hrs. OPERATION: SP2321A86B - 1986 TIME: 1.0 Hr. DLR. CODING: Basic Part No. 2001 - Code: 56 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Customer Interest for Brake Pad: > 841628 > Jul > 84 > Brakes (Rear) - Accelerated Wear Brake Pad: Customer Interest Brakes (Rear) - Accelerated Wear Articles No. 84-16-28 BRAKE, REAR - ACCELERATED WEAR - VEHICLES WITH 11" DIAMETER REAR BRAKES LIGHT TRUCKS 1975-84 E & F-100/150 & BRONCO This article supersedes TSB article 83-25-18, dated December 13, 1983, to include all 1975-84 E & F-100/150 & Bronco vehicles that have 11" diameter rear brakes. Some E and F-100/150 and Bronco vehicles subjected to extreme duty cycles in urban delivery/service operations may experience accelerated rear brake wear. A service kit(E0UZ-2C178-A) has been released for these vehicles and should be installed in its entirety if the vehicle exhibits any of the following conditions: ^ Side to side imbalance in rear braking effectiveness. ^ Side to side imbalance in rear brake lining wear. ^ Excessive heat ("blued" shoes and/or drums). The service kit consists of replacement front and rear brake linings, rear wheel cylinders and a proportioning valve. These parts must be installed per the appropriate shop manual installation procedure. NOTE: If a misalignment between the drum braking surface and the shoe ledge guides of the brake backing plate is suspected, refer to TSB 82-24 for the appropriate service procedures before installing the service kit (E0UZ-2C178-A). PART NUMBER PART NAME CLASS E0UZ-2C178-A Brake Service Kit C Front/Rear Services OTHER APPLICABLE ARTICLES: 82-24-17 ARTICLE SUPERSEDED: 83-25-18 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP2178A83 TIME: 2.3 Hrs. DLR. CODING: Basic Part No. 2200 Code: 30 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Customer Interest for Brake Pad: > 83519 > Mar > 83 > Rear Brakes - Abnormal Rear Brake Wear Brake Pad: Customer Interest Rear Brakes - Abnormal Rear Brake Wear Article No. 83-5-19 BRAKE - REAR - WEAR - AMBULANCE VEHICLES, E & F 250/350 OVER 8500 GVW LIGHT TRUCKS 1976-82 E-350 Ambulance vehicles that experience unusual rear brake wear should be updated to the 1982 ambulance brake package level using the following procedure. (1976 through 1982 vehicles may be affected). Technical Service Bulletin 80-21, Article 80-21-15, dated October 24, 1980 addressed procedures that helped to minimize rear brake wear. This method is still recommended. Under certain circumstances of severe customer usage involving extremely high loads and frequent stopping (i.e., emergency vehicles), the following procedure is also recommended. Perform operation described in Technical Service Bulletin 80-21, Article 80-21-15 and update the front and rear brake systems as follows: ^ Install new front disc brake pad and lining assemblies, D9TZ-2001-A. NOTE: Service or replace disc brake rotor assemblies, if required. ^ 12 x 3 Inch Brakes - Install new rear brake shoe and lining assemblies (Part Number D7TZ-2200-A). Color Code: Secondary 1 green/ 1 red, primary 1 pink/1 yellow right and lefthand. ^ 12 x 2.5 Inch Brakes - Install new rear brake shoe and lining assemblies, (Part Number D7TZ-2200-B). Color Code: Secondary 1 white/1 white primary 1 red/ 1 yellow right and lefthand. ^ Inspect rear brake wheel cylinder; checking cylinder size. Replace 1-1/16 inch diameter R.H. and L.H. wheel cylinder assemblies with 1 inch diameter R.H. and L.H. wheel cylinder assemblies (D6TZ-2261- A/R.H. and D6TZ-2262-A/L.H.). ^ Replace upper brake shoe retracting spring (green) C6TZ-2296-A with C6TZ-2035-A (red). ^ Replace valve with D9TA-2B524-AA. ^ Bleed hydraulic system as outlined in the 1977-1983 Light Truck Shop Manual. ^ Lining Conditioning Procedure Owners should be informed that unnecessary brake wear can be avoided only if the following burnish procedure is performed prior to putting an emergency vehicle into service: ^ 100 moderate snub stops from 40 to 20 mph. ^ 10 stops from 60 to 0 mph at 1/2 mile intervals at maximum deceleration without wheel lock-up. NOTE: These heavy duty shoe and lining service kits must be used in applications specified in the Ford Light Truck Parts Catalog or the Ford Technical Service Bulletin specifying mandatory front linings, rear wheel cylinders and installation procedures for vehicles not originally equipped with these linings. PART NUMBER PART NAME CLASS D9TZ-2001-A Front Shoe & Lining Kit B D7TZ-2200-A Heavy Duty Lining Kit 12" x 3" BM D7TZ-2200-B Heavy Duty Lining Kit 12" x 2.5" B D6TZ-2261-A Wheel Cylinder 1.0" RH A D6TZ-2262-A Wheel Cylinder 1.0" LH A C6TZ-2035-A Retracting Spring Rear Brake A D9TZ-2B257-A Valve C OTHER APPLICABLE ARTICLES: 81-15-19, 80-21-15 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION/TIME: Refer to the Labor Time Standards Manual for applicable operation and time. DLR. CODING: Basic Part No. R2007 Code: 30 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 86813 > Apr > 86 > Front Disc Brakes Squealing Noise Brake Pad: All Technical Service Bulletins Front Disc Brakes - Squealing Noise Article No. 86-8-13 BRAKES - FRONT DISC - SQUEAL LIGHT TRUCK 1980-86 E100/350, F100/350, BRONCO If the subject vehicles are experiencing a brake squeal concern, they should be serviced by installing insulator pads. Information in TSB 85-3-10 should not be used, this new service action supersedes the previous article with updated information. The following procedures and precautions should be observed when servicing front brake squeal concerns. ^ Remove the caliper and clean the sliding surfaces with a wire brush. Apply a light coating of ESAM1C172-A(D7AZ-19590-A) lubricant to both surfaces. Be careful not to get lube on rotors or linings. Wipe any excess lube off after assembly. Visually inspect rotors for any obvious damage or scoring. ^ Check the front wheel bearing end play adjustment. Adjust the front wheel bearings using the procedures included in the Light Truck Shop Manual, Sections 11-10 and 11-12. NOTE: The disc brake caliper and pads must be removed from the spindle prior to adjusting the front wheel bearings. ^ Clean lining and rotor surfaces. Remove any uneven glaze buildup on lining and rotor braking surfaces by sanding with medium to fine sandpaper or emery cloth. Uniform rotor sanding can be accomplished by holding the paper against the rotor braking surface while manually turning the rotor. ^ Remove any loose insulator material from the pad backing plates with sandpaper or an appropriate solvent. This procedure applies only to the following models: 1980-86 E100/150, F100/150, Bronco, F250 4x2 under 6900 lbs. GVW (single piston calipers). ^ Install the service insulator (E1TZ-2B321-A) to the backing plate of the OUTBOARD pad and lining assembly (both L.H. and R.H. brake). Bond the insulator to the back side of the brake pad assembly with ESA-M1C140-A1 (D7AZ-19554-C) adhesive. Apply adhesive to the light color side of each insulator. Assure that insulator is centered on backing plate and that directions for applying adhesive are followed. This procedure is for 1980-86 F250 4x2 over 6900 lbs. GVW, F250 4x4, F350, E250/350 (dual piston calipers). ^ Install the service insulator (E1TZ-2B321-B) to the back side of the INBOARD pad and lining assembly (both L.H. and R.H. brake). Bond the insulator to the backing plate and lining assembly using the previously listed procedure. ^ Install the service shim (E6TZ-2B321-A) to the back side of the outboard pad and lining assembly (both L.H. and R.H. brake) by clipping the shim over the straight edge of the backing plate. Be sure the shim is fully seated and centered on the straight edge of the backing plate. NOTE: For dual piston caliper application only. ^ Reinstall caliper to the spindle assembly. NOTE: DO NOT replace linings unless required for wear or additional concerns (Shop Manual, Section 12-24). PART NUMBER PART NAME CLASS E1TZ-2B321-A Insulator BM E1TZ-2B321-B Insulator BM E6TZ-2B321-A Shim B D7AZ-19590-A Lubricant A D7AZ-19554-C Adhesive AM OTHER APPLICABLE ARTICLES: Supersedes 85-3-10 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP2321A86A - 1980-85 TIME: 1.1 Hrs. OPERATION: SP2321A86B - 1986 TIME: 1.0 Hr. DLR. CODING: Basic Part No. 2001 - Code: 56 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 841628 > Jul > 84 > Brakes (Rear) Accelerated Wear Brake Pad: All Technical Service Bulletins Brakes (Rear) - Accelerated Wear Articles No. 84-16-28 BRAKE, REAR - ACCELERATED WEAR - VEHICLES WITH 11" DIAMETER REAR BRAKES LIGHT TRUCKS 1975-84 E & F-100/150 & BRONCO This article supersedes TSB article 83-25-18, dated December 13, 1983, to include all 1975-84 E & F-100/150 & Bronco vehicles that have 11" diameter rear brakes. Some E and F-100/150 and Bronco vehicles subjected to extreme duty cycles in urban delivery/service operations may experience accelerated rear brake wear. A service kit(E0UZ-2C178-A) has been released for these vehicles and should be installed in its entirety if the vehicle exhibits any of the following conditions: ^ Side to side imbalance in rear braking effectiveness. ^ Side to side imbalance in rear brake lining wear. ^ Excessive heat ("blued" shoes and/or drums). The service kit consists of replacement front and rear brake linings, rear wheel cylinders and a proportioning valve. These parts must be installed per the appropriate shop manual installation procedure. NOTE: If a misalignment between the drum braking surface and the shoe ledge guides of the brake backing plate is suspected, refer to TSB 82-24 for the appropriate service procedures before installing the service kit (E0UZ-2C178-A). PART NUMBER PART NAME CLASS E0UZ-2C178-A Brake Service Kit C Front/Rear Services OTHER APPLICABLE ARTICLES: 82-24-17 ARTICLE SUPERSEDED: 83-25-18 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP2178A83 TIME: 2.3 Hrs. DLR. CODING: Basic Part No. 2200 Code: 30 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Pad: > 83519 > Mar > 83 > Rear Brakes - Abnormal Rear Brake Wear Brake Pad: All Technical Service Bulletins Rear Brakes - Abnormal Rear Brake Wear Article No. 83-5-19 BRAKE - REAR - WEAR - AMBULANCE VEHICLES, E & F 250/350 OVER 8500 GVW LIGHT TRUCKS 1976-82 E-350 Ambulance vehicles that experience unusual rear brake wear should be updated to the 1982 ambulance brake package level using the following procedure. (1976 through 1982 vehicles may be affected). Technical Service Bulletin 80-21, Article 80-21-15, dated October 24, 1980 addressed procedures that helped to minimize rear brake wear. This method is still recommended. Under certain circumstances of severe customer usage involving extremely high loads and frequent stopping (i.e., emergency vehicles), the following procedure is also recommended. Perform operation described in Technical Service Bulletin 80-21, Article 80-21-15 and update the front and rear brake systems as follows: ^ Install new front disc brake pad and lining assemblies, D9TZ-2001-A. NOTE: Service or replace disc brake rotor assemblies, if required. ^ 12 x 3 Inch Brakes - Install new rear brake shoe and lining assemblies (Part Number D7TZ-2200-A). Color Code: Secondary 1 green/ 1 red, primary 1 pink/1 yellow right and lefthand. ^ 12 x 2.5 Inch Brakes - Install new rear brake shoe and lining assemblies, (Part Number D7TZ-2200-B). Color Code: Secondary 1 white/1 white primary 1 red/ 1 yellow right and lefthand. ^ Inspect rear brake wheel cylinder; checking cylinder size. Replace 1-1/16 inch diameter R.H. and L.H. wheel cylinder assemblies with 1 inch diameter R.H. and L.H. wheel cylinder assemblies (D6TZ-2261- A/R.H. and D6TZ-2262-A/L.H.). ^ Replace upper brake shoe retracting spring (green) C6TZ-2296-A with C6TZ-2035-A (red). ^ Replace valve with D9TA-2B524-AA. ^ Bleed hydraulic system as outlined in the 1977-1983 Light Truck Shop Manual. ^ Lining Conditioning Procedure Owners should be informed that unnecessary brake wear can be avoided only if the following burnish procedure is performed prior to putting an emergency vehicle into service: ^ 100 moderate snub stops from 40 to 20 mph. ^ 10 stops from 60 to 0 mph at 1/2 mile intervals at maximum deceleration without wheel lock-up. NOTE: These heavy duty shoe and lining service kits must be used in applications specified in the Ford Light Truck Parts Catalog or the Ford Technical Service Bulletin specifying mandatory front linings, rear wheel cylinders and installation procedures for vehicles not originally equipped with these linings. PART NUMBER PART NAME CLASS D9TZ-2001-A Front Shoe & Lining Kit B D7TZ-2200-A Heavy Duty Lining Kit 12" x 3" BM D7TZ-2200-B Heavy Duty Lining Kit 12" x 2.5" B D6TZ-2261-A Wheel Cylinder 1.0" RH A D6TZ-2262-A Wheel Cylinder 1.0" LH A C6TZ-2035-A Retracting Spring Rear Brake A D9TZ-2B257-A Valve C OTHER APPLICABLE ARTICLES: 81-15-19, 80-21-15 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION/TIME: Refer to the Labor Time Standards Manual for applicable operation and time. DLR. CODING: Basic Part No. R2007 Code: 30 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Technical Service Bulletins > Page 2302 Brake Pad: Service and Repair REMOVAL 1. To avoid fluid overflow when pistons are pushed into caliper, remove some brake fluid from master cylinder. 2. Raise vehicle and remove wheel assembly. 3. Remove key retaining screw then, using a brass drift and hammer, drive out the key and spring. 4. Remove caliper and its support by rotating the key and spring end out and away from the rotor. Slide opposite end of caliper clear of the slide in the support and off the rotor. Place caliper on tie rod or axle. Do not allow the brake hose to support weight of caliper, as this can damage the hose. 5. Remove caliper brake shoe anti-rattle spring and inner and outer shoe and lining assemblies. 6. Clean and inspect caliper assembly. Thoroughly clean areas of caliper and support that contact during the sliding action of the caliper. Fig. 3 Bottoming caliper pistons Fig. 4 Caliper spring & key INSTALLATION 1. Place used inner lining and shoe assembly over the pistons, then place a C-clamp on the caliper housing midway between the two pistons over the lining and shoe assembly, Fig. 3. Tighten the clamp until pistons are bottomed in caliper, then remove C-clamp and lining and shoe assembly. 2. Install the new inner and outer shoe and lining assemblies, and the anti-rattle spring. 3. Position caliper rail into the slide on the support and rotate the caliper onto rotor. 4. Position the key and spring, Fig. 4, then install the subassembly between the caliper and support. Note that the spring is between the key and caliper and that spring tangs overlap the ends of the key. 5. If necessary use a screwdriver to hold caliper against support assembly, then using a hammer, drive the key and spring into position aligning the correct notch with the existing hole in the support. 6. Install the key to support retaining screw and torque to 12---20 ft. lbs. 7. Install wheel assembly and lower vehicle. Check brake fluid level and add as necessary with heavy duty brake fluid. 8. Depress brake pedal several times to seat linings on rotor. Do not move vehicle until a firm brake pedal has been obtained. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Customer Interest for Brake Rotor/Disc: > 872414 > Dec > 87 > Brakes - Shudder and Vibration On Application Brake Rotor/Disc: Customer Interest Brakes - Shudder and Vibration On Application Article No. 87-24-14 BRAKE - ROTORS - SHUDDER AND VIBRATION DURING APPLICATION - CRACKED ROTOR ASSEMBLY VIBRATION AND SHUDDER - DURING BRAKE APPLICATION - CRACKED ROTOR LIGHT TRUCK: 1980-87 E-250/350, F-250/350 ISSUE: Shudder and vibration during brake application may be caused by cracks in the braking surface of the front disc brake rotors. Units that may be affected are 1980-87 E-250/350 and 4 x 2 F-250/350 vehicles with single rear wheels (SRW) and 1980-87 E-350 and 4 x 2 F-350 vehicles with dual rear wheels (DRW). ACTION: To correct this, install new design heavy-duty brake rotors. Refer to the Application Chart below for the correct service part numbers. PART NUMBER PART NAME CLASS E0TZ-1102-J Disc Brake Rotor B E0TZ-1102-K Disc Brake Rotor B E0TZ-1102-L Disc Brake Rotor B E7TZ-1102-C Disc Brake Rotor B E7TZ-1102-D Disc Brake Rotor B OTHER APPLICABLE ARTICLES: Supersedes 87-16-16 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION: SP872414A TIME: 1.0 Hr. DLR. CODING: Basic Part No. 1102 - Code: 01 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 872414 > Dec > 87 > Brakes Shudder and Vibration On Application Brake Rotor/Disc: All Technical Service Bulletins Brakes - Shudder and Vibration On Application Article No. 87-24-14 BRAKE - ROTORS - SHUDDER AND VIBRATION DURING APPLICATION - CRACKED ROTOR ASSEMBLY VIBRATION AND SHUDDER - DURING BRAKE APPLICATION - CRACKED ROTOR LIGHT TRUCK: 1980-87 E-250/350, F-250/350 ISSUE: Shudder and vibration during brake application may be caused by cracks in the braking surface of the front disc brake rotors. Units that may be affected are 1980-87 E-250/350 and 4 x 2 F-250/350 vehicles with single rear wheels (SRW) and 1980-87 E-350 and 4 x 2 F-350 vehicles with dual rear wheels (DRW). ACTION: To correct this, install new design heavy-duty brake rotors. Refer to the Application Chart below for the correct service part numbers. PART NUMBER PART NAME CLASS E0TZ-1102-J Disc Brake Rotor B E0TZ-1102-K Disc Brake Rotor B E0TZ-1102-L Disc Brake Rotor B E7TZ-1102-C Disc Brake Rotor B E7TZ-1102-D Disc Brake Rotor B OTHER APPLICABLE ARTICLES: Supersedes 87-16-16 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION: SP872414A TIME: 1.0 Hr. DLR. CODING: Basic Part No. 1102 - Code: 01 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 2316 Brake Rotor/Disc: Specifications Front Nominal Thickness 1.185 in Minimum Thickness 1.12 in Thickness Variation (Parallelism) 0.0007 in Run Out (TIR) 0.003 in Finish 15-80 micro-in Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications Brake Drum: Specifications Rear Inside Diameter 11.031 in Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Installation Brake Drum: Service and Repair Installation 1. Clean ledge pads on backing plate, sanding lightly to bare metal. 2. Apply suitable lubricant to retracting and hold-down spring contacts on brake shoes and backing plate. 3. Apply suitable lubricant to threads and socket end of adjusting screw. 4. Install upper retracting spring on primary and secondary shoes and position shoe assembly on backing plate with wheel cylinder pushrods in shoe slots. 5. Install brake shoe hold-down springs. 6. Install brake shoe adjustment screw assembly with the slot in the head of adjustment screw facing primary shoe, lower retracting spring, adjusting lever spring, and adjusting lever assembly, and connect adjusting cable to adjusting lever. Socket end of each adjusting screw is stamped ``R'' or ``L'' to indicate use on right or left side of vehicle. Adjusting pivot nuts can be identified by number of lines machined around body of nut. Two lines indicate righthand nut and one line indicates lefthand nut. 7. Position cable in cable guide and install cable anchor fitting on the anchor pin. 8. Install parking brake assembly in anchor pin and secure with retaining nut behind backing plate. 9. On vehicles with full-floating axles, install brake drums as follows: a. Place brake drum on hub and install attaching screws, bolts, or bolts and nuts. b. Place hub and drum as an assembly on axle and start adjusting nut. c. Adjust wheel bearing nut and install wheel bearing lock washer and lock nut. See REAR AXLE for procedure. d. Install new gasket and the bolts and lock washers. e. Install wheel and tire assembly. f. Adjust brakes. Refer to individual truck chapter for correct adjustment procedure. 10. On vehicles with semi-floating axles, install brake drums as follows: a. Adjust brakes. Refer to individual truck chapter for correct adjustment procedure. b. Install drum. c. Install brake drum retaining nuts and tighten securely. d. Install wheel on axle shaft flange studs against drum, and tighten retaining nuts. 11. If any hydraulic connections have been opened, perform system brake bleeding procedures. 12. Check master cylinder fluid level, filling as necessary. 13. Check brake pedal for proper feel and return. 14. Lower vehicle and road test. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Service and Repair > Installation > Page 2323 Brake Drum: Service and Repair Removal Assembled View 1. Raise and support vehicle. 2. Remove hub cap, then the wheel and tire assembly. 3. On vehicles with full-floating axles, remove brake drums as follows: a. Loosen rear brake shoe adjustment screw. b. Remove rear axle retaining bolts and lock washers, axle shaft, and gasket. c. Remove wheel bearing locknut, lock washer, and adjusting nut. d. Remove hub and drum from axle. e. Remove brake drum-to-hub retaining screws, bolts, or bolts and nuts, then remove brake drum from hub. 4. On vehicles with semi-floating axles, remove brake drums as follows: a. Remove brake drum retaining nuts. b. Remove brake drum. If brake lining is dragging on brake drum, back off brake adjustment by rotating adjusting screw. 5. Remove parking brake lever assembly retaining nut from behind backing plate and remove parking brake lever assembly. 6. Remove adjusting cable assembly from anchor pin, cable guide, and adjusting lever, Fig. 1. 7. Remove brake shoe retracting springs. 8. Remove brake shoe hold-down springs. 9. Remove brake shoes and adjusting screw assembly. 10. Disassemble adjusting screw assembly. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Customer Interest for Brake Shoe: > 841628 > Jul > 84 > Brakes (Rear) - Accelerated Wear Brake Shoe: Customer Interest Brakes (Rear) - Accelerated Wear Articles No. 84-16-28 BRAKE, REAR - ACCELERATED WEAR - VEHICLES WITH 11" DIAMETER REAR BRAKES LIGHT TRUCKS 1975-84 E & F-100/150 & BRONCO This article supersedes TSB article 83-25-18, dated December 13, 1983, to include all 1975-84 E & F-100/150 & Bronco vehicles that have 11" diameter rear brakes. Some E and F-100/150 and Bronco vehicles subjected to extreme duty cycles in urban delivery/service operations may experience accelerated rear brake wear. A service kit(E0UZ-2C178-A) has been released for these vehicles and should be installed in its entirety if the vehicle exhibits any of the following conditions: ^ Side to side imbalance in rear braking effectiveness. ^ Side to side imbalance in rear brake lining wear. ^ Excessive heat ("blued" shoes and/or drums). The service kit consists of replacement front and rear brake linings, rear wheel cylinders and a proportioning valve. These parts must be installed per the appropriate shop manual installation procedure. NOTE: If a misalignment between the drum braking surface and the shoe ledge guides of the brake backing plate is suspected, refer to TSB 82-24 for the appropriate service procedures before installing the service kit (E0UZ-2C178-A). PART NUMBER PART NAME CLASS E0UZ-2C178-A Brake Service Kit C Front/Rear Services OTHER APPLICABLE ARTICLES: 82-24-17 ARTICLE SUPERSEDED: 83-25-18 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP2178A83 TIME: 2.3 Hrs. DLR. CODING: Basic Part No. 2200 Code: 30 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Customer Interest for Brake Shoe: > 83519 > Mar > 83 > Rear Brakes - Abnormal Rear Brake Wear Brake Shoe: Customer Interest Rear Brakes - Abnormal Rear Brake Wear Article No. 83-5-19 BRAKE - REAR - WEAR - AMBULANCE VEHICLES, E & F 250/350 OVER 8500 GVW LIGHT TRUCKS 1976-82 E-350 Ambulance vehicles that experience unusual rear brake wear should be updated to the 1982 ambulance brake package level using the following procedure. (1976 through 1982 vehicles may be affected). Technical Service Bulletin 80-21, Article 80-21-15, dated October 24, 1980 addressed procedures that helped to minimize rear brake wear. This method is still recommended. Under certain circumstances of severe customer usage involving extremely high loads and frequent stopping (i.e., emergency vehicles), the following procedure is also recommended. Perform operation described in Technical Service Bulletin 80-21, Article 80-21-15 and update the front and rear brake systems as follows: ^ Install new front disc brake pad and lining assemblies, D9TZ-2001-A. NOTE: Service or replace disc brake rotor assemblies, if required. ^ 12 x 3 Inch Brakes - Install new rear brake shoe and lining assemblies (Part Number D7TZ-2200-A). Color Code: Secondary 1 green/ 1 red, primary 1 pink/1 yellow right and lefthand. ^ 12 x 2.5 Inch Brakes - Install new rear brake shoe and lining assemblies, (Part Number D7TZ-2200-B). Color Code: Secondary 1 white/1 white primary 1 red/ 1 yellow right and lefthand. ^ Inspect rear brake wheel cylinder; checking cylinder size. Replace 1-1/16 inch diameter R.H. and L.H. wheel cylinder assemblies with 1 inch diameter R.H. and L.H. wheel cylinder assemblies (D6TZ-2261- A/R.H. and D6TZ-2262-A/L.H.). ^ Replace upper brake shoe retracting spring (green) C6TZ-2296-A with C6TZ-2035-A (red). ^ Replace valve with D9TA-2B524-AA. ^ Bleed hydraulic system as outlined in the 1977-1983 Light Truck Shop Manual. ^ Lining Conditioning Procedure Owners should be informed that unnecessary brake wear can be avoided only if the following burnish procedure is performed prior to putting an emergency vehicle into service: ^ 100 moderate snub stops from 40 to 20 mph. ^ 10 stops from 60 to 0 mph at 1/2 mile intervals at maximum deceleration without wheel lock-up. NOTE: These heavy duty shoe and lining service kits must be used in applications specified in the Ford Light Truck Parts Catalog or the Ford Technical Service Bulletin specifying mandatory front linings, rear wheel cylinders and installation procedures for vehicles not originally equipped with these linings. PART NUMBER PART NAME CLASS D9TZ-2001-A Front Shoe & Lining Kit B D7TZ-2200-A Heavy Duty Lining Kit 12" x 3" BM D7TZ-2200-B Heavy Duty Lining Kit 12" x 2.5" B D6TZ-2261-A Wheel Cylinder 1.0" RH A D6TZ-2262-A Wheel Cylinder 1.0" LH A C6TZ-2035-A Retracting Spring Rear Brake A D9TZ-2B257-A Valve C OTHER APPLICABLE ARTICLES: 81-15-19, 80-21-15 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION/TIME: Refer to the Labor Time Standards Manual for applicable operation and time. DLR. CODING: Basic Part No. R2007 Code: 30 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Shoe: > 841628 > Jul > 84 > Brakes (Rear) Accelerated Wear Brake Shoe: All Technical Service Bulletins Brakes (Rear) - Accelerated Wear Articles No. 84-16-28 BRAKE, REAR - ACCELERATED WEAR - VEHICLES WITH 11" DIAMETER REAR BRAKES LIGHT TRUCKS 1975-84 E & F-100/150 & BRONCO This article supersedes TSB article 83-25-18, dated December 13, 1983, to include all 1975-84 E & F-100/150 & Bronco vehicles that have 11" diameter rear brakes. Some E and F-100/150 and Bronco vehicles subjected to extreme duty cycles in urban delivery/service operations may experience accelerated rear brake wear. A service kit(E0UZ-2C178-A) has been released for these vehicles and should be installed in its entirety if the vehicle exhibits any of the following conditions: ^ Side to side imbalance in rear braking effectiveness. ^ Side to side imbalance in rear brake lining wear. ^ Excessive heat ("blued" shoes and/or drums). The service kit consists of replacement front and rear brake linings, rear wheel cylinders and a proportioning valve. These parts must be installed per the appropriate shop manual installation procedure. NOTE: If a misalignment between the drum braking surface and the shoe ledge guides of the brake backing plate is suspected, refer to TSB 82-24 for the appropriate service procedures before installing the service kit (E0UZ-2C178-A). PART NUMBER PART NAME CLASS E0UZ-2C178-A Brake Service Kit C Front/Rear Services OTHER APPLICABLE ARTICLES: 82-24-17 ARTICLE SUPERSEDED: 83-25-18 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP2178A83 TIME: 2.3 Hrs. DLR. CODING: Basic Part No. 2200 Code: 30 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Shoe: > 83519 > Mar > 83 > Rear Brakes - Abnormal Rear Brake Wear Brake Shoe: All Technical Service Bulletins Rear Brakes - Abnormal Rear Brake Wear Article No. 83-5-19 BRAKE - REAR - WEAR - AMBULANCE VEHICLES, E & F 250/350 OVER 8500 GVW LIGHT TRUCKS 1976-82 E-350 Ambulance vehicles that experience unusual rear brake wear should be updated to the 1982 ambulance brake package level using the following procedure. (1976 through 1982 vehicles may be affected). Technical Service Bulletin 80-21, Article 80-21-15, dated October 24, 1980 addressed procedures that helped to minimize rear brake wear. This method is still recommended. Under certain circumstances of severe customer usage involving extremely high loads and frequent stopping (i.e., emergency vehicles), the following procedure is also recommended. Perform operation described in Technical Service Bulletin 80-21, Article 80-21-15 and update the front and rear brake systems as follows: ^ Install new front disc brake pad and lining assemblies, D9TZ-2001-A. NOTE: Service or replace disc brake rotor assemblies, if required. ^ 12 x 3 Inch Brakes - Install new rear brake shoe and lining assemblies (Part Number D7TZ-2200-A). Color Code: Secondary 1 green/ 1 red, primary 1 pink/1 yellow right and lefthand. ^ 12 x 2.5 Inch Brakes - Install new rear brake shoe and lining assemblies, (Part Number D7TZ-2200-B). Color Code: Secondary 1 white/1 white primary 1 red/ 1 yellow right and lefthand. ^ Inspect rear brake wheel cylinder; checking cylinder size. Replace 1-1/16 inch diameter R.H. and L.H. wheel cylinder assemblies with 1 inch diameter R.H. and L.H. wheel cylinder assemblies (D6TZ-2261- A/R.H. and D6TZ-2262-A/L.H.). ^ Replace upper brake shoe retracting spring (green) C6TZ-2296-A with C6TZ-2035-A (red). ^ Replace valve with D9TA-2B524-AA. ^ Bleed hydraulic system as outlined in the 1977-1983 Light Truck Shop Manual. ^ Lining Conditioning Procedure Owners should be informed that unnecessary brake wear can be avoided only if the following burnish procedure is performed prior to putting an emergency vehicle into service: ^ 100 moderate snub stops from 40 to 20 mph. ^ 10 stops from 60 to 0 mph at 1/2 mile intervals at maximum deceleration without wheel lock-up. NOTE: These heavy duty shoe and lining service kits must be used in applications specified in the Ford Light Truck Parts Catalog or the Ford Technical Service Bulletin specifying mandatory front linings, rear wheel cylinders and installation procedures for vehicles not originally equipped with these linings. PART NUMBER PART NAME CLASS D9TZ-2001-A Front Shoe & Lining Kit B D7TZ-2200-A Heavy Duty Lining Kit 12" x 3" BM D7TZ-2200-B Heavy Duty Lining Kit 12" x 2.5" B D6TZ-2261-A Wheel Cylinder 1.0" RH A D6TZ-2262-A Wheel Cylinder 1.0" LH A C6TZ-2035-A Retracting Spring Rear Brake A D9TZ-2B257-A Valve C OTHER APPLICABLE ARTICLES: 81-15-19, 80-21-15 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION/TIME: Refer to the Labor Time Standards Manual for applicable operation and time. DLR. CODING: Basic Part No. R2007 Code: 30 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Page 2345 Brake Shoe: Adjustments Fig. 5 Service brake adjustment The hydraulic drum brakes are self-adjusting and require a manual adjustment only after brake shoes have been relined or replaced. The adjustment is made as follows: 1. Determine inside diameter of brake drum using brake adjustment gauge, Fig. 5. 2. Reverse tool and adjust brake shoes to fit the gauge. Hold automatic adjusting lever out of engagement while rotating adjusting screw to avoid damaging screw slots. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Installation Brake Shoe: Service and Repair Installation 1. Clean ledge pads on backing plate, sanding lightly to bare metal. 2. Apply suitable lubricant to retracting and hold-down spring contacts on brake shoes and backing plate. 3. Apply suitable lubricant to threads and socket end of adjusting screw. 4. Install upper retracting spring on primary and secondary shoes and position shoe assembly on backing plate with wheel cylinder pushrods in shoe slots. 5. Install brake shoe hold-down springs. 6. Install brake shoe adjustment screw assembly with the slot in the head of adjustment screw facing primary shoe, lower retracting spring, adjusting lever spring, and adjusting lever assembly, and connect adjusting cable to adjusting lever. Socket end of each adjusting screw is stamped ``R'' or ``L'' to indicate use on right or left side of vehicle. Adjusting pivot nuts can be identified by number of lines machined around body of nut. Two lines indicate righthand nut and one line indicates lefthand nut. 7. Position cable in cable guide and install cable anchor fitting on the anchor pin. 8. Install parking brake assembly in anchor pin and secure with retaining nut behind backing plate. 9. On vehicles with full-floating axles, install brake drums as follows: a. Place brake drum on hub and install attaching screws, bolts, or bolts and nuts. b. Place hub and drum as an assembly on axle and start adjusting nut. c. Adjust wheel bearing nut and install wheel bearing lock washer and lock nut. See REAR AXLE for procedure. d. Install new gasket and the bolts and lock washers. e. Install wheel and tire assembly. f. Adjust brakes. Refer to individual truck chapter for correct adjustment procedure. 10. On vehicles with semi-floating axles, install brake drums as follows: a. Adjust brakes. Refer to individual truck chapter for correct adjustment procedure. b. Install drum. c. Install brake drum retaining nuts and tighten securely. d. Install wheel on axle shaft flange studs against drum, and tighten retaining nuts. 11. If any hydraulic connections have been opened, perform system brake bleeding procedures. 12. Check master cylinder fluid level, filling as necessary. 13. Check brake pedal for proper feel and return. 14. Lower vehicle and road test. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Service and Repair > Installation > Page 2348 Brake Shoe: Service and Repair Removal Assembled View 1. Raise and support vehicle. 2. Remove hub cap, then the wheel and tire assembly. 3. On vehicles with full-floating axles, remove brake drums as follows: a. Loosen rear brake shoe adjustment screw. b. Remove rear axle retaining bolts and lock washers, axle shaft, and gasket. c. Remove wheel bearing locknut, lock washer, and adjusting nut. d. Remove hub and drum from axle. e. Remove brake drum-to-hub retaining screws, bolts, or bolts and nuts, then remove brake drum from hub. 4. On vehicles with semi-floating axles, remove brake drums as follows: a. Remove brake drum retaining nuts. b. Remove brake drum. If brake lining is dragging on brake drum, back off brake adjustment by rotating adjusting screw. 5. Remove parking brake lever assembly retaining nut from behind backing plate and remove parking brake lever assembly. 6. Remove adjusting cable assembly from anchor pin, cable guide, and adjusting lever, Fig. 1. 7. Remove brake shoe retracting springs. 8. Remove brake shoe hold-down springs. 9. Remove brake shoes and adjusting screw assembly. 10. Disassemble adjusting screw assembly. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Wheel Cylinder: > 841628 > Jul > 84 > Brakes (Rear) - Accelerated Wear Wheel Cylinder: Customer Interest Brakes (Rear) - Accelerated Wear Articles No. 84-16-28 BRAKE, REAR - ACCELERATED WEAR - VEHICLES WITH 11" DIAMETER REAR BRAKES LIGHT TRUCKS 1975-84 E & F-100/150 & BRONCO This article supersedes TSB article 83-25-18, dated December 13, 1983, to include all 1975-84 E & F-100/150 & Bronco vehicles that have 11" diameter rear brakes. Some E and F-100/150 and Bronco vehicles subjected to extreme duty cycles in urban delivery/service operations may experience accelerated rear brake wear. A service kit(E0UZ-2C178-A) has been released for these vehicles and should be installed in its entirety if the vehicle exhibits any of the following conditions: ^ Side to side imbalance in rear braking effectiveness. ^ Side to side imbalance in rear brake lining wear. ^ Excessive heat ("blued" shoes and/or drums). The service kit consists of replacement front and rear brake linings, rear wheel cylinders and a proportioning valve. These parts must be installed per the appropriate shop manual installation procedure. NOTE: If a misalignment between the drum braking surface and the shoe ledge guides of the brake backing plate is suspected, refer to TSB 82-24 for the appropriate service procedures before installing the service kit (E0UZ-2C178-A). PART NUMBER PART NAME CLASS E0UZ-2C178-A Brake Service Kit C Front/Rear Services OTHER APPLICABLE ARTICLES: 82-24-17 ARTICLE SUPERSEDED: 83-25-18 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP2178A83 TIME: 2.3 Hrs. DLR. CODING: Basic Part No. 2200 Code: 30 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cylinder: > 841628 > Jul > 84 > Brakes (Rear) Accelerated Wear Wheel Cylinder: All Technical Service Bulletins Brakes (Rear) - Accelerated Wear Articles No. 84-16-28 BRAKE, REAR - ACCELERATED WEAR - VEHICLES WITH 11" DIAMETER REAR BRAKES LIGHT TRUCKS 1975-84 E & F-100/150 & BRONCO This article supersedes TSB article 83-25-18, dated December 13, 1983, to include all 1975-84 E & F-100/150 & Bronco vehicles that have 11" diameter rear brakes. Some E and F-100/150 and Bronco vehicles subjected to extreme duty cycles in urban delivery/service operations may experience accelerated rear brake wear. A service kit(E0UZ-2C178-A) has been released for these vehicles and should be installed in its entirety if the vehicle exhibits any of the following conditions: ^ Side to side imbalance in rear braking effectiveness. ^ Side to side imbalance in rear brake lining wear. ^ Excessive heat ("blued" shoes and/or drums). The service kit consists of replacement front and rear brake linings, rear wheel cylinders and a proportioning valve. These parts must be installed per the appropriate shop manual installation procedure. NOTE: If a misalignment between the drum braking surface and the shoe ledge guides of the brake backing plate is suspected, refer to TSB 82-24 for the appropriate service procedures before installing the service kit (E0UZ-2C178-A). PART NUMBER PART NAME CLASS E0UZ-2C178-A Brake Service Kit C Front/Rear Services OTHER APPLICABLE ARTICLES: 82-24-17 ARTICLE SUPERSEDED: 83-25-18 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP2178A83 TIME: 2.3 Hrs. DLR. CODING: Basic Part No. 2200 Code: 30 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair Brake Bleeding: Service and Repair Bleed primary and secondary hydraulic brake systems separately, bleeding longest line first on each system. Do not allow reservoir to run dry during bleeding operation. Never reuse fluid that has been drained from hydraulic system. 1. Loosen master cylinder to hydraulic line nuts and wrap shop cloths around tubing below fitting to absorb escaping brake fluid. 2. Depress brake pedal slowly by hand to floor of cab, forcing air trapped in master cylinder out at fitting. 3. Hold pedal down and tighten fittings, then release brake pedal. Releasing brake pedal before fittings are tightened will allow air to enter the master cylinder. 4. Repeat steps 1 through 3 until air ceases to escape at fittings and brake pedal is firm. 5. Bleed rear brakes as follows: a. Pump pedal several times, then hold pedal down firmly. b. With pedal firmly depressed, open bleeder screw on one rear brake until pedal fades to floor, then close bleeder valve. c. Repeat procedure until a continuous flow of brake fluid is released from bleeder valve. d. Repeat steps 5a through 5c on other rear brake. 6. Bleed front brakes using same procedure as for rear brakes. 7. Fill master cylinder reservoirs to {1/4} inch from top of reservoirs. 8. Centralize the pressure differential control valve, if applicable, as follows: a. Turn ignition switch to ``ACC'' or ``On'' position. b. Push brake pedal down, allowing piston to center itself, turning off warning light. c. Turn ignition switch to ``OFF'' position. 9. Check brake operation and ensure pedal is firm, then road test vehicle. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 86621 > Mar > 86 > Front Disc Brakes Clunk During Braking Brake Caliper: Customer Interest Front Disc Brakes - Clunk During Braking Article No. 86-6-21 BRAKES - FRONT DISC - CLUNK LIGHT TRUCK 1980-85 E250/350, F250/350 Some 1980-85 250/350 Econoline and F Series vehicles over 6900 GVW are experiencing front disc brake clunk during braking. This concern can be corrected by using new caliper support keys and springs as outlined in the following procedure. 1. Remove the caliper and clean the sliding surfaces with a wire brush. Apply a light coat of ESAM1C172-A (D7AZ-19590-A) lubricant to both surfaces, being careful not to get lubricant on rotors or linings. 2. Check the front wheel bearing end play adjustment. Adjust the front wheel bearings using the Light Truck Shop Manual procedures, Section 11- 10 and 11-12. 3. Discard the old caliper support key and spring and reinstall the caliper using a new service key (D7TZ- 2B487-B) and spring (D7TZ-2B486-B). PART NUMBER PART NAME CLASS D7TZ-2B487-B Support Key A D7TZ-2B486-B Spring A D7AZ-19590-A Lubricant A OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP2487A86 TIME: 0.6 Hr. DLR. CODING: Basic Part No. 2B487 - Code: 33 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 86621 > Mar > 86 > Front Disc Brakes - Clunk During Braking Brake Caliper: All Technical Service Bulletins Front Disc Brakes - Clunk During Braking Article No. 86-6-21 BRAKES - FRONT DISC - CLUNK LIGHT TRUCK 1980-85 E250/350, F250/350 Some 1980-85 250/350 Econoline and F Series vehicles over 6900 GVW are experiencing front disc brake clunk during braking. This concern can be corrected by using new caliper support keys and springs as outlined in the following procedure. 1. Remove the caliper and clean the sliding surfaces with a wire brush. Apply a light coat of ESAM1C172-A (D7AZ-19590-A) lubricant to both surfaces, being careful not to get lubricant on rotors or linings. 2. Check the front wheel bearing end play adjustment. Adjust the front wheel bearings using the Light Truck Shop Manual procedures, Section 11- 10 and 11-12. 3. Discard the old caliper support key and spring and reinstall the caliper using a new service key (D7TZ- 2B487-B) and spring (D7TZ-2B486-B). PART NUMBER PART NAME CLASS D7TZ-2B487-B Support Key A D7TZ-2B486-B Spring A D7AZ-19590-A Lubricant A OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP2487A86 TIME: 0.6 Hr. DLR. CODING: Basic Part No. 2B487 - Code: 33 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal Brake Caliper: Service and Repair Caliper Removal Fig. 1 Bottoming caliper piston in cylinder bore 1. Remove a portion of brake fluid from master cylinder disc brake reservoir. 2. Raise and support vehicle and remove wheel and tire assembly. 3. Install eight inch C-clamp on caliper, Fig. 1, and tighten clamp to bottom piston in cylinder bore, then remove clamp. Do not use screwdriver or other edged tool to pry piston from rotor. 4. Remove key retaining screw, then using hammer and drift, drive out caliper support key and spring. 5. Remove caliper by pushing it downward against spindle assembly and rotating upper end upward and out of spindle assembly. 6. Disconnect hydraulic line from caliper. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal > Page 2381 Brake Caliper: Service and Repair Disassembling Caliper Fig. 2 Removing caliper piston Fig. 3 Exploded view of disc brake caliper assembly 1. Remove plug from caliper inlet port and drain fluid from caliper housing. 2. Position caliper on block of wood, Fig. 2. 3. Slowly and carefully apply low pressure air to caliper inlet port until piston pops out. 4. If piston is jammed or cocked and will not pop out, release air pressure and tap sharply on end of piston with soft hammer or plastic or rubber mallet to straighten piston, then apply air pressure again to remove piston. 5. Remove boot from piston and seal from caliper cylinder bore, Fig. 3. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal > Page 2382 Brake Caliper: Service and Repair Assembling Caliper 1. Lubricate piston seal with clean brake fluid and position seal in groove in cylinder bore. 2. Coat outside of piston and both beads of dust boot with clean brake fluid, then insert piston through dust boot until boot is around closed end of piston. 3. Hold piston and dust boot directly above caliper cylinder bore and use fingers to work bead of dust boot into groove near top of cylinder bore. 4. One bead is seated in groove, press straight down on piston until piston bottoms in bore. Ensure piston is not cocked in bore. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Caliper Removal > Page 2383 Brake Caliper: Service and Repair Caliper Installation 1. Position caliper on spindle assembly by pivoting caliper around support upper mounting surface, being careful not to tear or cut boot as boot slips over inner shoe. 2. Using brake adjusting tool or screwdriver, hold upper machined surface of caliper against surface of support assembly and install new caliper support spring and new caliper support key. 3. Using suitable mallet, drive key and spring assembly into position, then install key retaining screw and torque to 14---20 ft. lbs. 4. Connect hydraulic line to caliper. 5. Install wheel and tire assembly and lower vehicle to ground, then fill master cylinder as necessary with suitable brake fluid. 6. Firmly depress brake pedal several times to seat linings on rotor. 7. Perform brake bleeding procedures. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Locations Brake Fluid Pressure Sensor/Switch: Locations Frame Wiring. On LH Frame At No. 2 Crossmember Applicable to: 138 Standard Van Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Technical Service Bulletins > Customer Interest for Brake Proportioning/Combination Valve: > 841628 > Jul > 84 > Brakes (Rear) - Accelerated Wear Brake Proportioning/Combination Valve: Customer Interest Brakes (Rear) - Accelerated Wear Articles No. 84-16-28 BRAKE, REAR - ACCELERATED WEAR - VEHICLES WITH 11" DIAMETER REAR BRAKES LIGHT TRUCKS 1975-84 E & F-100/150 & BRONCO This article supersedes TSB article 83-25-18, dated December 13, 1983, to include all 1975-84 E & F-100/150 & Bronco vehicles that have 11" diameter rear brakes. Some E and F-100/150 and Bronco vehicles subjected to extreme duty cycles in urban delivery/service operations may experience accelerated rear brake wear. A service kit(E0UZ-2C178-A) has been released for these vehicles and should be installed in its entirety if the vehicle exhibits any of the following conditions: ^ Side to side imbalance in rear braking effectiveness. ^ Side to side imbalance in rear brake lining wear. ^ Excessive heat ("blued" shoes and/or drums). The service kit consists of replacement front and rear brake linings, rear wheel cylinders and a proportioning valve. These parts must be installed per the appropriate shop manual installation procedure. NOTE: If a misalignment between the drum braking surface and the shoe ledge guides of the brake backing plate is suspected, refer to TSB 82-24 for the appropriate service procedures before installing the service kit (E0UZ-2C178-A). PART NUMBER PART NAME CLASS E0UZ-2C178-A Brake Service Kit C Front/Rear Services OTHER APPLICABLE ARTICLES: 82-24-17 ARTICLE SUPERSEDED: 83-25-18 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP2178A83 TIME: 2.3 Hrs. DLR. CODING: Basic Part No. 2200 Code: 30 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Proportioning/Combination Valve: > 841628 > Jul > 84 > Brakes (Rear) - Accelerated Wear Brake Proportioning/Combination Valve: All Technical Service Bulletins Brakes (Rear) Accelerated Wear Articles No. 84-16-28 BRAKE, REAR - ACCELERATED WEAR - VEHICLES WITH 11" DIAMETER REAR BRAKES LIGHT TRUCKS 1975-84 E & F-100/150 & BRONCO This article supersedes TSB article 83-25-18, dated December 13, 1983, to include all 1975-84 E & F-100/150 & Bronco vehicles that have 11" diameter rear brakes. Some E and F-100/150 and Bronco vehicles subjected to extreme duty cycles in urban delivery/service operations may experience accelerated rear brake wear. A service kit(E0UZ-2C178-A) has been released for these vehicles and should be installed in its entirety if the vehicle exhibits any of the following conditions: ^ Side to side imbalance in rear braking effectiveness. ^ Side to side imbalance in rear brake lining wear. ^ Excessive heat ("blued" shoes and/or drums). The service kit consists of replacement front and rear brake linings, rear wheel cylinders and a proportioning valve. These parts must be installed per the appropriate shop manual installation procedure. NOTE: If a misalignment between the drum braking surface and the shoe ledge guides of the brake backing plate is suspected, refer to TSB 82-24 for the appropriate service procedures before installing the service kit (E0UZ-2C178-A). PART NUMBER PART NAME CLASS E0UZ-2C178-A Brake Service Kit C Front/Rear Services OTHER APPLICABLE ARTICLES: 82-24-17 ARTICLE SUPERSEDED: 83-25-18 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP2178A83 TIME: 2.3 Hrs. DLR. CODING: Basic Part No. 2200 Code: 30 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Technical Service Bulletins > Page 2400 Brake Proportioning/Combination Valve: Description and Operation EXCEPT AEROSTAR, BRONCO II & 1983---87 RANGER These vehicles use a pressure differential valve, a metering valve (1980---84) and a proportioning valve which are combined in a single unit. These valves sense unbalanced pressure between front and rear brakes. Loss of pressure in either the primary or secondary brake system causes pressure differential valve to move off center and illuminate brake warning light. After system is replaced and brakes are bled, the valve centers itself, turning off warning light. The brake warning light switch is mounted on top of the valve body casting above the pressure differential valve tapered shoulder groove. When the valve is centered, spring loaded switch plunger fits into the tapered shoulder groove. The switch contacts are open, interrupting electrical continuity to the brake warning light on the instrument panel. The metering valve is located in the front end of the control valve housing between the front brake system inlet port and the right and left front brake outlet ports. This valve regulates hydraulic fluid pressure to the front disc brakes. The proportioning valve used on some models is located at the bottom of the housing between the rear brake system inlet and outlet ports. This valve regulates rear brake system hydraulic pressure. A plug and tube seat is pressed into the rear end of the central bore. A hole through the center of the plug and tube seal directs hydraulic fluid from the valve to the rear brake system outlet port. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Brake Master Cylinder - Rebuilding Procedure Brake Master Cylinder: Technical Service Bulletins Brake Master Cylinder - Rebuilding Procedure Article No. 83-19-14 BRAKE MASTER CYLINDERS - REBUILDING PROCEDURE LIGHT TRUCKS 1981-84 ALL LIGHT TRUCKS Rebuilding of brake master cylinders during the vehicle warranty period for the subject vehicles has been authorized. Service kits (Base Part Number 2004) are now available for all light truck series vehicles. The following procedure is recommended for rebuilding: DISASSEMBLY 1. Clean the outside of the master cylinder and remove the filler cover and diaphragm. Drain and discard any brake fluid that remains in the cylinder. 2. Depress the primary piston and remove snap ring from retaining groove at the rear of the master cylinder bore. 3. Remove primary piston assembly from the master cylinder bore and inspect for seal damage or twisting. Record condition of piston assembly on service order and discard assembly. 4. Remove the secondary piston assembly by directing compressed air into the outlet port at the blind end of the bore while plugging the other outlet port. Inspect for seal damage or twisting. Record condition of piston assembly on service order and discard assembly. 5. Inspect the master cylinder bore for signs of etching, pitting, scoring or other damage. a. If bore is damaged, discard and replace with new master cylinder assembly. Do not attempt to hone bore. b. If bore is not damaged, rebuild master cylinder assembly using the proper service kit and the procedure outlined below. ASSEMBLY 1. Clean the master cylinder body with clean isopropyl alcohol to remove any contamination. 2. Dip the service kit piston assemblies in clean brake fluid (ESA-M6C25-A) to lubricate seals. 3. Carefully insert the complete secondary piston assembly in the master cylinder bore. 4. Carefully insert the primary piston assembly in the master cylinder bore. 5. Depress the primary piston and install the snap ring in the cylinder bore groove. 6. On manual brake vehicles, install the push rod retainer onto the push rod and install into the primary piston. Make sure the retainer is properly seated and holding the push rod securely. 7. Install the cover and gasket on the master cylinder assembly and secure into position with the retainer. OTHER APPLICABLE ARTICLES: 80-21-14 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION/TIME: Refer to the Labor Time Standards Manual for applicable operation and time. DLR. CODING: Basic Part No. 2004 Code: 53 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Page 2405 Brake Master Cylinder: Description and Operation This master cylinder contains a double hydraulic cylinder with one fluid reservoir on Aerostar models or two fluid reservoirs on other models as well as primary and secondary hydraulic pistons. The rear wheel brakes are connected to the secondary outlet port and are actuated by the secondary piston assembly. The front wheel brakes are connected to the primary outlet port(s), nearest the dash panel, and are actuated by the primary piston assembly. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Page 2406 Brake Master Cylinder: Adjustments Fig. 1 Adjusting Piston Rod To check adjustment of pushrod, fabricate a gauge and position it against the master cylinder mounting surface as shown in Fig. 1. Adjust pushrod screw by turning it until the end just touches inner edge of slot in the gauge. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Technical Service Bulletins > Page 2407 Brake Master Cylinder: Service and Repair LESS POWER BRAKES 1. Disconnect battery ground cable. 2. Disconnect stop lamp switch electrical connectors. 3. Remove retaining nut, shoulder bolt, spacers and bushing securing master cylinder pushrod to brake pedal. 4. Remove stop lamp switch from brake pedal. 5. Disconnect brake lines from master cylinder, then remove attaching screws or nuts and the master cylinder. 6. Remove boot from master cylinder push rod. 7. Reverse procedure to install. POWER BRAKES 1. Depress brake pedal, with engine off, to release vacuum from power brake unit. 2. Disconnect brake lines from master cylinder. 3. Remove master cylinder-to-power brake unit attaching bolts, then lift master cylinder from mounting studs. 4. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Wheel Cylinder: > 841628 > Jul > 84 > Brakes (Rear) Accelerated Wear Wheel Cylinder: Customer Interest Brakes (Rear) - Accelerated Wear Articles No. 84-16-28 BRAKE, REAR - ACCELERATED WEAR - VEHICLES WITH 11" DIAMETER REAR BRAKES LIGHT TRUCKS 1975-84 E & F-100/150 & BRONCO This article supersedes TSB article 83-25-18, dated December 13, 1983, to include all 1975-84 E & F-100/150 & Bronco vehicles that have 11" diameter rear brakes. Some E and F-100/150 and Bronco vehicles subjected to extreme duty cycles in urban delivery/service operations may experience accelerated rear brake wear. A service kit(E0UZ-2C178-A) has been released for these vehicles and should be installed in its entirety if the vehicle exhibits any of the following conditions: ^ Side to side imbalance in rear braking effectiveness. ^ Side to side imbalance in rear brake lining wear. ^ Excessive heat ("blued" shoes and/or drums). The service kit consists of replacement front and rear brake linings, rear wheel cylinders and a proportioning valve. These parts must be installed per the appropriate shop manual installation procedure. NOTE: If a misalignment between the drum braking surface and the shoe ledge guides of the brake backing plate is suspected, refer to TSB 82-24 for the appropriate service procedures before installing the service kit (E0UZ-2C178-A). PART NUMBER PART NAME CLASS E0UZ-2C178-A Brake Service Kit C Front/Rear Services OTHER APPLICABLE ARTICLES: 82-24-17 ARTICLE SUPERSEDED: 83-25-18 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP2178A83 TIME: 2.3 Hrs. DLR. CODING: Basic Part No. 2200 Code: 30 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Cylinder: > 841628 > Jul > 84 > Brakes (Rear) - Accelerated Wear Wheel Cylinder: All Technical Service Bulletins Brakes (Rear) - Accelerated Wear Articles No. 84-16-28 BRAKE, REAR - ACCELERATED WEAR - VEHICLES WITH 11" DIAMETER REAR BRAKES LIGHT TRUCKS 1975-84 E & F-100/150 & BRONCO This article supersedes TSB article 83-25-18, dated December 13, 1983, to include all 1975-84 E & F-100/150 & Bronco vehicles that have 11" diameter rear brakes. Some E and F-100/150 and Bronco vehicles subjected to extreme duty cycles in urban delivery/service operations may experience accelerated rear brake wear. A service kit(E0UZ-2C178-A) has been released for these vehicles and should be installed in its entirety if the vehicle exhibits any of the following conditions: ^ Side to side imbalance in rear braking effectiveness. ^ Side to side imbalance in rear brake lining wear. ^ Excessive heat ("blued" shoes and/or drums). The service kit consists of replacement front and rear brake linings, rear wheel cylinders and a proportioning valve. These parts must be installed per the appropriate shop manual installation procedure. NOTE: If a misalignment between the drum braking surface and the shoe ledge guides of the brake backing plate is suspected, refer to TSB 82-24 for the appropriate service procedures before installing the service kit (E0UZ-2C178-A). PART NUMBER PART NAME CLASS E0UZ-2C178-A Brake Service Kit C Front/Rear Services OTHER APPLICABLE ARTICLES: 82-24-17 ARTICLE SUPERSEDED: 83-25-18 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP2178A83 TIME: 2.3 Hrs. DLR. CODING: Basic Part No. 2200 Code: 30 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > Parking Brake Cables - New Plastic Coated Design Parking Brake Cable: Technical Service Bulletins Parking Brake Cables - New Plastic Coated Design Article No. 83-14-19 PARKING BRAKE CABLE - PLASTIC COATED - SERVICE RELEASE LIGHT TRUCKS 1980-82 E, F & BRONCO New plastic coated parking brake cables have been released to service 1980-82 E, F and Bronco vehicles. These new cables will result in improved resistance to corrosion and contamination and should be considered for vehicles. The rear cables are packaged in kit form and require both cables to be installed when replacing the prior level cables. The kit also contains other rear brake components that should be installed at that time. New plastic coated front parking brake cables are also released for all 1980-82 F Series, Bronco, and Econoline vehicles. It is not always necessary to replace the front cables along with the rear cables; the vehicle must be inspected first to determine which cables require replacement. REAR PARKING BRAKE KITS Model Kit Number F-100/150/Bronco 11" Rear Brake E0TZ-2A753-A F-100 10" Rear Brake E0TZ-2A753-B F-250/350 12" Rear Brake E0TZ-2A753-C E-100/150 11" Rear Brake E0UZ-2A753-A E-250/350 12" Rear Brake E0UZ-2A753-B FRONT PARKING BRAKE CABLE Model Wheel Base Part Number F Series 117" E0TZ-2853-K 133" E0TZ-2853-L 138" E0TZ-2853-M 155" E0TZ-2853-N 161" E0TZ-2853-R Bronco E0TZ-2853-S Econoline 124" E0UZ-2853-A 138" E0UZ-2853-B 158" E0UZ-2853-C 176" E0UZ-2853-D PART NUMBER PART NAME CLASS E0TZ-2A753-A 11" Rear Parking Brake Kit C F100/150/Bronco E0TZ-2A753-B 10" Rear Parking Brake Kit C F100 E0TZ-2A753-C 12" Rear Parking Brake Kit C F250/350 E0UZ-2A753-A 11" Rear Parking Brake Kit C E100/150 E0UZ-2A753-B 12" Rear Parking Brake Kit C E250/350 E0TZ-2853-K Front Parking Brake Cable C F Series 117" E0TZ-2853-L Front Parking Brake Cable C F Series 133" E0TZ-2853-M Front Parking Brake Cable C F Series 138" E0TZ-2853-N Front Parking Brake Cable C F Series 155" E0TZ-2853-R Front Parking Brake Cable C F Series 161" E0TZ-2853-S Front Parking Brake Cable C Bronco E0UZ-2853-A Front Parking Brake Cable C Econoline 124" E0UZ-2853-B Front Parking Brake Cable C Econoline 138" E0UZ-2853-C Front Parking Brake Cable C Econoline 158" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Technical Service Bulletins > Parking Brake Cables - New Plastic Coated Design > Page 2426 E0UZ-2853-D Front Parking Brake Cable C Econoline 176" OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Adjustments Parking Brake Control: Adjustments EXC. 1985-87 E-350 W/ORSCHEIN PARKING BRAKE LEVER 1. Position parking brake pedal to fully released position, then tighten equalizer nut 6 full turns while preventing automatic adjuster from turning. 2. Depress parking brake pedal fully and measure cable tension. Cable tension should meet the following specifications: 1980 front cable with parking brake set in second notch, 120-160 lbs., and 1981-87 rear cable with parking brake fully applied, 350 lbs. 3. If cable tension is not within specifications, repeat step 3 and recheck. 4. Release parking brake and check for rear wheel drag. If brake drag is noted on 1983---87 E-250---350 & F-250---350 models and 1980---82 E-250---350 models after brake adjustment, remove rear drums and measure clearance between parking brake lever and cam plate. This clearance should be .015 inch with brakes fully released. If clearance is not .015 inch, repeat cable adjustment procedure. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Top Of Parking Brake Assembly Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation Vacuum Brake Booster: Description and Operation The single and tandem vacuum boosters are self contained vacuum hydraulic power braking units. These are vacuum suspended units that use vacuum and atmospheric pressure for their power. On gasoline engine vehicles, vacuum is supplied through a fitting in the intake manifold. On diesel engine vehicles, vacuum is supplied through a vacuum pump. The three basic elements of the booster are the vacuum power chamber, mechanically actuated booster check valve and a hydraulic dual master cylinder which supplies hydraulic pressure to the brake system. The vacuum power chamber consists of a front and rear shell, diaphragm, diaphragm plate, hydraulic pushrod and vacuum diaphragm return spring. The mechanically actuated booster check valve controls the degree of power brake application in accordance with foot pressure applied to the valve operating rod through the brake pedal linkage. This valve is integral with the vacuum power diaphragm. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > Page 2437 Vacuum Brake Booster: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect stop lamp switch electrical connectors. 3. Support underside of master cylinder, then remove power brake unit-to-master cylinder attaching nuts. 4. Remove vacuum hose between manifold and power brake unit, or power brake unit check valve. Remove check valve, if equipped. 5. Separate power brake unit and master cylinder, leaving master cylinder supported far enough away to allow removal of power brake unit. 6. On models equipped with push rod mounted stop lamp switch, remove retaining pin, then slide switch, push rod, spacers and bushing off brake pedal pin. 7. On models equipped with brake pedal mounted stop lamp switch, remove attaching bolt, nut and plastic bushing, then disconnect power brake unit push rod from brake pedal. 8. Remove power brake unit attaching bolts and the power brake unit. 9. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Locations Brake Fluid Pressure Sensor/Switch: Locations Frame Wiring. On LH Frame At No. 2 Crossmember Applicable to: 138 Standard Van Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Top Of Parking Brake Assembly Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Pedal Position Switch <--> [Clutch Switch] > Component Information > Testing and Inspection Clutch Pedal Position Switch: Testing and Inspection Manual Transmission Vehicles Only This switch functions magnetically. Do not use magnetized tools near this switch. 1. If the switch is open when the clutch pedal is released, speed control will not operate. This must be corrected before making any other tests. Use only a multimeter of 5000 ohm/volt rating or higher when performing the clutch switch test. 2. Disconnect switch pigtail connector from speed control harness connector and connect an ohmmeter to the two switch connector terminals. 3. With clutch pedal in the fully released position, the resistance should be less than 5 ohms. With clutch pedal fully depressed, the circuit should be open. 4. If switch does not function as described, remove and replace switch. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Component Information > Service and Repair Ignition Switch: Service and Repair Fig. 3 Ignition switch replacement 1. Disconnect battery ground cable. 2. Remove steering column shroud and lower the steering column. 3. Disconnect electrical connector from switch, then remove 2 switch attaching nuts. 4. Lift switch up to disengage actuator rod, then remove switch from vehicle, Fig. 3. 5. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations Location For C6 Transmission Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Locations > Page 2456 Neutral Safety Switch: Service and Repair Fig. 8 Neutral safety switch replacement. Exc. automatic overdrive transmission EXC. AUTOMATIC OVERDRIVE TRANSMISSION 1. Disconnect battery ground cable. 2. Remove downshift linkage rod return spring from low-reverse servo cover. 3. Apply penetrating oil to outer lever attaching nut, then remove transmission downshift outer lever attaching nut and lever. 4. Remove neutral safety switch attaching bolts, then disconnect electrical connectors and remove switch from vehicle. 5. To install, position switch on transmission and secure with attaching bolts. Do not tighten bolts at this time. 6. Place transmission manual lever in neutral position, then insert a .091 inch gauge pin through gauge pin holes, Fig. 8. 7. Tighten switch attaching bolts, then remove gauge pin. 8. Install outer downshift lever and retaining nut. 9. Install downshift linkage rod return spring between lever and retaining clip on low-reverse servo cover. 10. Reconnect electrical connectors, then check operation of switch. W/AUTOMATIC OVERDRIVE TRANSMISSION 1. Disconnect battery ground cable. 2. Raise and support vehicle. 3. Disconnect electrical connector at neutral safety switch, lifting connector straight up. 4. Using suitable socket, remove neutral safety switch and O-ring seal. 5. Reverse procedure to install, installing new O-ring seal. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations RH Fender Apron w/EEC On RH Fender Apron Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins > Auxiliary Battery Relay - Improved Design Battery: Technical Service Bulletins Auxiliary Battery Relay - Improved Design Article No. 85-21-12 WIRING - AUXILIARY BATTERY RELAY-IMPROVED WEATHER RESISTANT DESIGN LIGHT TRUCK 1973-86 E, F SERIES, BRONCO Figure 14 - ECONOLINE LOCATION Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins > Auxiliary Battery Relay - Improved Design > Page 2465 Figure 15 - F-150/350 TRUCK AND BRONCO LOCATION An improved weather resistant auxiliary battery relay has been released for the subject vehicles equipped with an auxiliary battery. (See Figures 14 and 15) The new relay (E5TZ-14677-A) is a direct replacement for the old relay, D3TZ-14377-B, which has been discontinued. PART NUMBER PART NAME CLASS E5TZ-14677-A Auxiliary Battery Relay A OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Battery > Component Information > Technical Service Bulletins > Page 2466 BATTERY Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Diode Trio, Alternator > Component Information > Testing and Inspection Diode Trio: Testing and Inspection Fig. 9 Regulator plug. Jumper wire connection Test Procedure 1. Disconnect electric choke, if equipped. 2. Disconnect voltage regulator wiring connector. 3. Connect a jumper wire between the ``A'' and ``F'' terminals of the voltage regulator wiring connector, Fig. 9. 4. Connect voltmeter to battery clamps. Then, start and idle engine. 5. Observe and note voltmeter reading. 6. Move the voltmeter positive lead to the alternator ``S'' terminal and note voltage reading. Test Results 1. If voltmeter reading is within {1/2} of battery voltage, the diodes are satisfactory. 2. If voltmeter reading is approximately 1.5 volts, the alternator has a shorted negative diode or a grounded stator winding. 3. If voltmeter reading is approximately 1.5 volts less than battery voltage, the alternator has a shorted positive diode. 4. If voltage reading is approximately 1 to 1.5 volts less than {1/2} battery voltage, the alternator has an open positive diode. 5. If voltage reading is 1 to 1.5 volts above {1/2} battery voltage, the alternator has an open negative diode. 6. Reconnect electric choke into circuit after tests are completed, if equipped. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Rectifier Diode / Bridge, Alternator > Component Information > Technical Service Bulletins > Alternator - Rectifier Bench Test Procedure Rectifier Diode / Bridge: Technical Service Bulletins Alternator - Rectifier Bench Test Procedure Article No. 84-3-5 ALTERNATOR - RECTIFIER BENCH TEST PROCEDURE FORD ALL LINCOLN-MERCURY ALL LIGHT TRUCKS ALL MEDIUM/HEAVY TRUCKS ALL During a recent dealer survey, it was discovered that some technicians are using digital meters for alternator testing, despite specific instructions in the Shop Manual to the contrary. The digital meters cannot be used for checking rectifier assemblies or diodes in the alternator. This may explain a portion of non-defective rectifiers returned under warranty. Alternator Rectifier Testing Information The use of digital meters when bench testing an alternator rectifier assembly can cause misdiagnosis. It is recommended in the Shop Manual (Section 31) that a Rotunda Meter Model #059-00003, or equivalent, be used. Equivalent test meters must be of the "analog" type, not digital. A digital meter could only be used if it has a diode checking function. However, the readings should be compared with those of a new part to confirm the results. If the rectifier is found to be okay, check for possible pinched or grounded wires to the inside of the housing. Then reassemble the alternator with the tested rectifier. The Shop Manual Charging System Diagnostic Procedure should be reviewed to confirm proper procedures were used. Remember to first check for proper drive belt tension and proper wire connections at the alternator and voltage regulator. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Rectifier Diode / Bridge, Alternator > Component Information > Technical Service Bulletins > Page 2476 Rectifier Diode / Bridge: Testing and Inspection Fig. 13 Testing diode trio Fig. 14 Alternator w/integral regulator rectifier short or grounded & stator grounded test RECTIFIER SHORT OR GROUNDED & STATOR GROUNDED TEST Using a suitable ohmmeter, connect one probe to the alternator BAT terminal, Figs. 13 and 14, and the other probe to the STA terminal (rear blade terminal). Then, reverse the ohmmeter probes and repeat the test. A reading of about 6.5 ohms should be obtained in one direction and no needle movement with the probes reversed. A reading in both directions indicates a bad positive diode, a grounded positive diode plate or a grounded BAT terminal. Perform the same test using the STA and GND (ground) terminals of the alternator. A reading in both directions indicates either a bad negative diode, a grounded stator winding, a grounded stator terminal, a grounded positive diode plate, or a grounded BAT terminal. Infinite readings (no needle movement) in all four probe positions in the preceding tests indicates an open STA terminal lead connection inside the alternator. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Rectifier Diode / Bridge, Alternator > Component Information > Technical Service Bulletins > Page 2477 Fig. 15 Testing rectifier bridge diodes FIELD OPEN OR SHORT CIRCUIT TEST Exc. Alternators W/Integral Regulators Using a suitable ohmmeter, connect the alternator field terminal with one probe and the ground terminal with the other probe, Fig. 15. Then, spin the alternator pulley. The ohmmeter reading should be between 2.4 and 25 ohms on 1980 units, 2.4 and 100 ohms on all 1981-85 units and 1986-87 models less IAR system, and should fluctuate while the pulley is turning. An infinite reading (no meter movement) indicates an open brush lead, worn or stuck brushes, or a bad rotor assembly. An ohmmeter reading of less than 2.4 ohms indicates a grounded brush assembly, a grounded field terminal or a bad rotor. Fig. 16 Alternator w/integral regulator field open or short circuit test Alternators W/Integral Regulators 1. Using a suitable ohmmeter, connect regulator A blade terminal with one probe and the regulator ``F'' screw head with the other probe, Fig. 16. 2. Spin the alternator pulley and note meter reading, then reverse probes and repeat step 1. In one probe direction ohmmeter reading should be between 2.2 and 100 ohms and may fluctuate while pulley is turning. In the other direction, reading should fluctuate between 2.2 and approximately 9 ohms. 3. An infinite reading (no meter movement) in one direction and approximately 9 ohms in the other, indicates an open brush lead, worn or stuck brushes, defective rotor or a loose regulator to brush holder attaching screw. 4. An ohmmeter reading less than 2.2 ohms in both directions indicates a shorted or defective regulator. 5. An ohmmeter reading significantly over 9 ohms in both directions indicates a defective regulator or loose ``F'' terminal screw. 6. Connect alternator rear housing with one ohmmeter probe and touch the other probe to the regulator ``F'' terminal. Reverse probes and repeat test. Ohmmeter reading should be infinite in one probe direction and approximately 9 ohms in the other. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Rectifier Diode / Bridge, Alternator > Component Information > Technical Service Bulletins > Page 2478 7. If ohmmeter reads less than infinite at either point, a grounded brush lead, grounded rotor or defective regulator is indicated. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Stator, Alternator > Component Information > Testing and Inspection Stator: Testing and Inspection Fig. 13 Testing diode trio Fig. 14 Alternator w/integral regulator rectifier short or grounded & stator grounded test RECTIFIER SHORT OR GROUNDED & STATOR GROUNDED TEST Using a suitable ohmmeter, connect one probe to the alternator BAT terminal, Figs. 13 and 14, and the other probe to the STA terminal (rear blade terminal). Then, reverse the ohmmeter probes and repeat the test. A reading of about 6.5 ohms should be obtained in one direction and no needle movement with the probes reversed. A reading in both directions indicates a bad positive diode, a grounded positive diode plate or a grounded BAT terminal. Perform the same test using the STA and GND (ground) terminals of the alternator. A reading in both directions indicates either a bad negative diode, a grounded stator winding, a grounded stator terminal, a grounded positive diode plate, or a grounded BAT terminal. Infinite readings (no needle movement) in all four probe positions in the preceding tests indicates an open STA terminal lead connection inside the alternator. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Stator, Alternator > Component Information > Testing and Inspection > Page 2482 Fig. 15 Testing rectifier bridge diodes FIELD OPEN OR SHORT CIRCUIT TEST Exc. Alternators W/Integral Regulators Using a suitable ohmmeter, connect the alternator field terminal with one probe and the ground terminal with the other probe, Fig. 15. Then, spin the alternator pulley. The ohmmeter reading should be between 2.4 and 25 ohms on 1980 units, 2.4 and 100 ohms on all 1981-85 units and 1986-87 models less IAR system, and should fluctuate while the pulley is turning. An infinite reading (no meter movement) indicates an open brush lead, worn or stuck brushes, or a bad rotor assembly. An ohmmeter reading of less than 2.4 ohms indicates a grounded brush assembly, a grounded field terminal or a bad rotor. Fig. 16 Alternator w/integral regulator field open or short circuit test Alternators W/Integral Regulators 1. Using a suitable ohmmeter, connect regulator A blade terminal with one probe and the regulator ``F'' screw head with the other probe, Fig. 16. 2. Spin the alternator pulley and note meter reading, then reverse probes and repeat step 1. In one probe direction ohmmeter reading should be between 2.2 and 100 ohms and may fluctuate while pulley is turning. In the other direction, reading should fluctuate between 2.2 and approximately 9 ohms. 3. An infinite reading (no meter movement) in one direction and approximately 9 ohms in the other, indicates an open brush lead, worn or stuck brushes, defective rotor or a loose regulator to brush holder attaching screw. 4. An ohmmeter reading less than 2.2 ohms in both directions indicates a shorted or defective regulator. 5. An ohmmeter reading significantly over 9 ohms in both directions indicates a defective regulator or loose ``F'' terminal screw. 6. Connect alternator rear housing with one ohmmeter probe and touch the other probe to the regulator ``F'' terminal. Reverse probes and repeat test. Ohmmeter reading should be infinite in one probe direction and approximately 9 ohms in the other. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Stator, Alternator > Component Information > Testing and Inspection > Page 2483 7. If ohmmeter reads less than infinite at either point, a grounded brush lead, grounded rotor or defective regulator is indicated. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Specifications Voltage Regulator: Specifications Measure battery voltage and record figure. With engine operating off idle and all secondary electrical systems turned off, regulated voltage should be no greater than 2 volts above recorded figure. Turn on headlights and set heater blower to high. Regulated voltage off idle should be no less than 0.5 volts above recorded figure. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Starting System > Clutch Pedal Position Switch <--> [Clutch Switch] > Component Information > Testing and Inspection Clutch Pedal Position Switch: Testing and Inspection Manual Transmission Vehicles Only This switch functions magnetically. Do not use magnetized tools near this switch. 1. If the switch is open when the clutch pedal is released, speed control will not operate. This must be corrected before making any other tests. Use only a multimeter of 5000 ohm/volt rating or higher when performing the clutch switch test. 2. Disconnect switch pigtail connector from speed control harness connector and connect an ohmmeter to the two switch connector terminals. 3. With clutch pedal in the fully released position, the resistance should be less than 5 ohms. With clutch pedal fully depressed, the circuit should be open. 4. If switch does not function as described, remove and replace switch. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Resistor <--> [Ignition Ballast Resistor] > Component Information > Description and Operation Ignition Resistor: Description and Operation The ballast resistor, (wire type), maintains a specific resistance between the positive (Batt.) terminal of the ignition coil connector and the wiring harness connector. It is not in operation during engine cranking enabling the coil to receive a hotter signal for starting. Once the engine is running, the resistor is used to protect the coil from voltage overload. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Resistor <--> [Ignition Ballast Resistor] > Component Information > Description and Operation > Page 2494 Ignition Resistor: Testing and Inspection 1. Disconnect module connector with red and white wires then, ignition coil connector. 2. Using a suitable ohmmeter, measure resistance between Batt. terminal of ignition coil connector and wiring harness connector wire that joins red wire in module connector. 3. If resistance is 0.8---1.6 ohms, ballast resistor is satisfactory. If resistance is less than 0.8 ohms or greater than 1.6 ohms, replace ballast resistor. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Diagrams > Connector Views Ignition Lock: Connector Views For Connector Views, please refer to: Ignition Switch/Diagrams, Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Diagrams > Connector Views > Page 2499 Ignition Lock: Electrical Diagrams For Wiring Diagrams, please refer to: Starting System/Diagrams, Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Diagrams > Page 2500 Ignition Lock: Service and Repair Fig. 1 Ignition lock replacement. Fixed steering column Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Diagrams > Page 2501 Fig. 2 Ignition lock replacement. Tilt steering column 1. Disconnect battery ground cable. 2. Remove steering wheel trim pad and steering wheel. 3. Shift transmission into Park on vehicles with automatic transmission, or into any gear on vehicles with manual transmission. 4. Insert a {1/8} inch diameter wire or small drift punch into retaining pin access slot and remove lock cylinder, Figs. 1 and 2, while depressing pin. The lock cylinder retaining pin is located adjacent to the hazard warning button on models with tilt steering column and inside the column near base of cylinder on models with fixed steering column. 5. To install, turn lock cylinder to On position and depress pin. 6. Install lock cylinder into housing. Turn ignition key to Off position after ensuring cylinder is fully seated and aligned into interlocking washer. 7. Turn the key to check for proper operation in all positions. 8. Install steering wheel and trim pad and reconnect battery ground cable. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Component Information > Service and Repair Ignition Switch: Service and Repair Fig. 3 Ignition switch replacement 1. Disconnect battery ground cable. 2. Remove steering column shroud and lower the steering column. 3. Disconnect electrical connector from switch, then remove 2 switch attaching nuts. 4. Lift switch up to disengage actuator rod, then remove switch from vehicle, Fig. 3. 5. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations Location For C6 Transmission Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Locations > Page 2508 Neutral Safety Switch: Service and Repair Fig. 8 Neutral safety switch replacement. Exc. automatic overdrive transmission EXC. AUTOMATIC OVERDRIVE TRANSMISSION 1. Disconnect battery ground cable. 2. Remove downshift linkage rod return spring from low-reverse servo cover. 3. Apply penetrating oil to outer lever attaching nut, then remove transmission downshift outer lever attaching nut and lever. 4. Remove neutral safety switch attaching bolts, then disconnect electrical connectors and remove switch from vehicle. 5. To install, position switch on transmission and secure with attaching bolts. Do not tighten bolts at this time. 6. Place transmission manual lever in neutral position, then insert a .091 inch gauge pin through gauge pin holes, Fig. 8. 7. Tighten switch attaching bolts, then remove gauge pin. 8. Install outer downshift lever and retaining nut. 9. Install downshift linkage rod return spring between lever and retaining clip on low-reverse servo cover. 10. Reconnect electrical connectors, then check operation of switch. W/AUTOMATIC OVERDRIVE TRANSMISSION 1. Disconnect battery ground cable. 2. Raise and support vehicle. 3. Disconnect electrical connector at neutral safety switch, lifting connector straight up. 4. Using suitable socket, remove neutral safety switch and O-ring seal. 5. Reverse procedure to install, installing new O-ring seal. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Armature > Component Information > Testing and Inspection > Armature & Field Grounded Circuit Test Starter Armature: Testing and Inspection Armature & Field Grounded Circuit Test Fig. 4 Field grounded circuit test connections 1. Connect jumper lead to positive battery terminal. 2. Connect negative voltmeter lead to negative battery terminal. 3. Touch positive voltmeter lead to commutator and jumper wire to armature. 4. If voltmeter indicates voltage, armature windings are grounded. 5. Make connections as shown, Fig. 4. If voltmeter indicates voltage, field windings are grounded. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Armature > Component Information > Testing and Inspection > Armature & Field Grounded Circuit Test > Page 2514 Starter Armature: Testing and Inspection Armature Open Circuit Test An open circuit in the armature can sometimes be detected by examining commutator for signs of burning. A spot burned on the commutator is caused by an arc formed every time a commutator segment connected to the open circuit winding passes under a brush. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision Technical Service Bulletin # 9211B1 Date: 920605 Starter Motor Brushes - Replacement Revision Article No. 92-11B-1 06/05/92 ^ SHOP MANUAL - 1982 THROUGH 1991 AS APPLICABLE - STARTER - POSITIVE ENGAGEMENT - STARTER MOTOR BRUSHES REPLACEMENT PROCEDURE FOR 4-INCH STARTERS REVISED/ADDED ^ SHOP MANUAL - 1990 AND 1991 AS APPLICABLE - STARTER - POSITIVE ENGAGEMENT STARTER SIZE SPECFICATION REVISED FORD: 1989 CROWN VICTORIA, ESCORT, TEMPO 1989-90 THUNDERBIRD 1989-91 MUSTANG, TAURUS LINCOLN-MERCURY: 1989 CONTINENTAL, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1989-90 COUGAR 1989-91 SABLE LIGHT TRUCK: 1982-91 BRONCO, ECONOLINE, F-150-350 SERIES 1983-91 RANGER 1984-90 BRONCO II 1986-91 AEROSTAR 1988-91 F SUPER DUTY ISSUE: The procedure for Starter Motor Brushes Replacement applicable to vehicles with 4-inch starters only is missing or incorrect in the "Starter-Positive Engagement" section of certain Shop Manuals. Additionally, the 1990 and 1991 Light Truck Shop Manuals incorrectly show a 3-inch starter in the Specifications Chart; the correct size is 4-inch. The following Shop Manuals are affected in the Sections indicated: ^ 1989 Domestic Car Lines: Section 28-02 ^ 1990 Mustang, Taurus/Sable, Thunderbird/Cougar: Section 28-02 ^ 1991 Mustang, Taurus/Sable: Section 28-02 ^ 1986 through 1988 Aerostar: Section 11-02 ^ 1989 Aerostar, Ranger, Bronco II: Section 03-06 ^ 1990 and 1991 Aerostar, Ranger, Bronco II: Section 03-06A ^ 1983 Ranger/1984 Bronco II (Reprint), 1984 through 1988 Ranger/Bronco II, 1982 through 1990 Light Truck-Engine: Section 28-02 ^ 1991 Light Truck-Engine: Section 03-06A ACTION: Refer to Disassembly and Assembly in this TSB article for the additional information. NOTE: THIS TSB ARTICLE INCLUDES REVISED PAGES FROM THE 1989, 1990 AND 1991 CAR SHOP MANUALS LISTED ABOVE, THE 1991 COMPACT TRUCK SHOP MANUAL AND THE 1990 AND 1991 LIGHT TRUCK SHOP MANUALS. ALTHOUGH NOT SHOWN, THE REVISIONS APPLY TO ALL LIGHT TRUCK AND COMPACT TRUCK MANUALS LISTED ABOVE. NOTE: THE PROCEDURE IN THIS TSB ARTICLE APPLIES TO VEHICLES WITH 4-INCH STARTERS ONLY. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 2519 290000 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 2520 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 2521 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 2522 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 2523 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 2524 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 2525 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 2526 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 2527 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 2528 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 2529 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 2530 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 2531 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 2532 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 2533 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 2534 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 2535 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 2536 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 2537 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 2538 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 2539 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Starter Relay: Locations RH Fender Apron w/EEC On RH Fender Apron Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Customer Interest for Fuse: > 851019 > May > 85 > A/C Blower Motor - Inoperative Fuse: Customer Interest A/C Blower Motor - Inoperative Article No. 85-10-19 AIR CONDITIONING - INOPERATIVE BLOWER MOTOR - DAMAGED FUSE OR FUSE HOLDER LIGHT TRUCK ALL 1985 AND PRIOR ECONOLINES When operating the A/C system for long periods of time with the blower motor set on high, the solder at the end of the A/C fuse melts with the additional loss of holder clip retention due to the heat build-up. A revised fuse holder is released to resolve the subject concern. The following procedure should be performed: 1. Check fuse for damage (solder melted at end of fuse). 2. Check fuse holder for proper retention of fuse (loss of fuse holder clip retention due to heat build-up). 3. If the fuse or fuse holder show no heat damage perform normal diagnostic procedures for inoperative A/C blower motor. If the fuse or fuse holder is found to be damaged as described in Steps 1 and 2 continue with Step 4. 4. Disconnect battery ground cable. 5. Remove two fuse panel retaining screws and turn fuse panel to expose back side of panel. 6. Locate the two orange wires (Circuit 181) leading to the A/C fuse holder. Cut both wires as close to the fuse panel as possible and remove the fuse holders from the fuse panel. 7. Install in-line fuse holder E5FZ-14517-A using 30 amp fuse D9ZZ-14526-G (green). Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Customer Interest for Fuse: > 851019 > May > 85 > A/C Blower Motor - Inoperative > Page 2552 Figure 23FUSE PANEL MOUNTED TO DASH PANEL LEFT OF STEERING COLUMN 8. Tape the fuse holder along the main wire harness as shown in Figure 23. 9. Re-install fuse panel, connect battery ground cable and check A/C system for proper operation. PART NUMBER PART NAME CLASS E5FZ-14517-A Fuse Holder R D9ZZ-14526-G Fuse A OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP14411A85 TIME: 0.4 Hr. DLR. CODING: Basic Part No. 14401 - Code: 28 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 851019 > May > 85 > A/C Blower Motor Inoperative Fuse: All Technical Service Bulletins A/C Blower Motor - Inoperative Article No. 85-10-19 AIR CONDITIONING - INOPERATIVE BLOWER MOTOR - DAMAGED FUSE OR FUSE HOLDER LIGHT TRUCK ALL 1985 AND PRIOR ECONOLINES When operating the A/C system for long periods of time with the blower motor set on high, the solder at the end of the A/C fuse melts with the additional loss of holder clip retention due to the heat build-up. A revised fuse holder is released to resolve the subject concern. The following procedure should be performed: 1. Check fuse for damage (solder melted at end of fuse). 2. Check fuse holder for proper retention of fuse (loss of fuse holder clip retention due to heat build-up). 3. If the fuse or fuse holder show no heat damage perform normal diagnostic procedures for inoperative A/C blower motor. If the fuse or fuse holder is found to be damaged as described in Steps 1 and 2 continue with Step 4. 4. Disconnect battery ground cable. 5. Remove two fuse panel retaining screws and turn fuse panel to expose back side of panel. 6. Locate the two orange wires (Circuit 181) leading to the A/C fuse holder. Cut both wires as close to the fuse panel as possible and remove the fuse holders from the fuse panel. 7. Install in-line fuse holder E5FZ-14517-A using 30 amp fuse D9ZZ-14526-G (green). Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 851019 > May > 85 > A/C Blower Motor Inoperative > Page 2558 Figure 23FUSE PANEL MOUNTED TO DASH PANEL LEFT OF STEERING COLUMN 8. Tape the fuse holder along the main wire harness as shown in Figure 23. 9. Re-install fuse panel, connect battery ground cable and check A/C system for proper operation. PART NUMBER PART NAME CLASS E5FZ-14517-A Fuse Holder R D9ZZ-14526-G Fuse A OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP14411A85 TIME: 0.4 Hr. DLR. CODING: Basic Part No. 14401 - Code: 28 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Page 2559 Fuse: Locations LH Shroud, Near Access Hole Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link B Fusible Link: Locations Fuse Link B Attached To Auxiliary Battery Relay Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link B > Page 2564 Fusible Link: Locations Fuse Link C Attached To Junction Block Or Auxiliary Battery Relay Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link B > Page 2565 Fusible Link: Locations Fuse Link D Attached To Junction Block Or Auxiliary Battery Relay Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link B > Page 2566 Fusible Link: Locations Fuse Link E At Starter Relay Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link B > Page 2567 Fusible Link: Locations Fuse Link B Attached To Auxiliary Battery Relay Fuse Link C Attached To Junction Block Or Auxiliary Battery Relay Fuse Link D Attached To Junction Block Or Auxiliary Battery Relay Fuse Link E At Starter Relay Fuse Link G At Starter Relay Fuse Link K At Junction Block Fuse Link L Connected To Junction Block Or Auxiliary Battery Relay Fuse Link M At Starter Relay Fuse Links A, G & H Attached To Starter Motor Relay Fuse Links G & H ( W/Ammeter) In Harness, RH Side Of Dash Panel Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Locations Multiple Junction Connector: Locations LH Side Of Dash Panel Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Protection Relay > Component Information > Locations Power Protection Relay: Locations In Engine Compartment On LH Fender Apron Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Protection Relay > Component Information > Locations Power Protection Relay: Locations In Engine Compartment On LH Fender Apron Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Customer Interest for Fuse: > 851019 > May > 85 > A/C Blower Motor - Inoperative Fuse: Customer Interest A/C Blower Motor - Inoperative Article No. 85-10-19 AIR CONDITIONING - INOPERATIVE BLOWER MOTOR - DAMAGED FUSE OR FUSE HOLDER LIGHT TRUCK ALL 1985 AND PRIOR ECONOLINES When operating the A/C system for long periods of time with the blower motor set on high, the solder at the end of the A/C fuse melts with the additional loss of holder clip retention due to the heat build-up. A revised fuse holder is released to resolve the subject concern. The following procedure should be performed: 1. Check fuse for damage (solder melted at end of fuse). 2. Check fuse holder for proper retention of fuse (loss of fuse holder clip retention due to heat build-up). 3. If the fuse or fuse holder show no heat damage perform normal diagnostic procedures for inoperative A/C blower motor. If the fuse or fuse holder is found to be damaged as described in Steps 1 and 2 continue with Step 4. 4. Disconnect battery ground cable. 5. Remove two fuse panel retaining screws and turn fuse panel to expose back side of panel. 6. Locate the two orange wires (Circuit 181) leading to the A/C fuse holder. Cut both wires as close to the fuse panel as possible and remove the fuse holders from the fuse panel. 7. Install in-line fuse holder E5FZ-14517-A using 30 amp fuse D9ZZ-14526-G (green). Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Customer Interest for Fuse: > 851019 > May > 85 > A/C Blower Motor - Inoperative > Page 2587 Figure 23FUSE PANEL MOUNTED TO DASH PANEL LEFT OF STEERING COLUMN 8. Tape the fuse holder along the main wire harness as shown in Figure 23. 9. Re-install fuse panel, connect battery ground cable and check A/C system for proper operation. PART NUMBER PART NAME CLASS E5FZ-14517-A Fuse Holder R D9ZZ-14526-G Fuse A OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP14411A85 TIME: 0.4 Hr. DLR. CODING: Basic Part No. 14401 - Code: 28 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 851019 > May > 85 > A/C Blower Motor - Inoperative Fuse: All Technical Service Bulletins A/C Blower Motor - Inoperative Article No. 85-10-19 AIR CONDITIONING - INOPERATIVE BLOWER MOTOR - DAMAGED FUSE OR FUSE HOLDER LIGHT TRUCK ALL 1985 AND PRIOR ECONOLINES When operating the A/C system for long periods of time with the blower motor set on high, the solder at the end of the A/C fuse melts with the additional loss of holder clip retention due to the heat build-up. A revised fuse holder is released to resolve the subject concern. The following procedure should be performed: 1. Check fuse for damage (solder melted at end of fuse). 2. Check fuse holder for proper retention of fuse (loss of fuse holder clip retention due to heat build-up). 3. If the fuse or fuse holder show no heat damage perform normal diagnostic procedures for inoperative A/C blower motor. If the fuse or fuse holder is found to be damaged as described in Steps 1 and 2 continue with Step 4. 4. Disconnect battery ground cable. 5. Remove two fuse panel retaining screws and turn fuse panel to expose back side of panel. 6. Locate the two orange wires (Circuit 181) leading to the A/C fuse holder. Cut both wires as close to the fuse panel as possible and remove the fuse holders from the fuse panel. 7. Install in-line fuse holder E5FZ-14517-A using 30 amp fuse D9ZZ-14526-G (green). Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 851019 > May > 85 > A/C Blower Motor - Inoperative > Page 2593 Figure 23FUSE PANEL MOUNTED TO DASH PANEL LEFT OF STEERING COLUMN 8. Tape the fuse holder along the main wire harness as shown in Figure 23. 9. Re-install fuse panel, connect battery ground cable and check A/C system for proper operation. PART NUMBER PART NAME CLASS E5FZ-14517-A Fuse Holder R D9ZZ-14526-G Fuse A OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP14411A85 TIME: 0.4 Hr. DLR. CODING: Basic Part No. 14401 - Code: 28 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Page 2594 Fuse: Locations LH Shroud, Near Access Hole Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link B Fusible Link: Locations Fuse Link B Attached To Auxiliary Battery Relay Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link B > Page 2599 Fusible Link: Locations Fuse Link C Attached To Junction Block Or Auxiliary Battery Relay Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link B > Page 2600 Fusible Link: Locations Fuse Link D Attached To Junction Block Or Auxiliary Battery Relay Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link B > Page 2601 Fusible Link: Locations Fuse Link E At Starter Relay Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link B > Page 2602 Fusible Link: Locations Fuse Link B Attached To Auxiliary Battery Relay Fuse Link C Attached To Junction Block Or Auxiliary Battery Relay Fuse Link D Attached To Junction Block Or Auxiliary Battery Relay Fuse Link E At Starter Relay Fuse Link G At Starter Relay Fuse Link K At Junction Block Fuse Link L Connected To Junction Block Or Auxiliary Battery Relay Fuse Link M At Starter Relay Fuse Links A, G & H Attached To Starter Motor Relay Fuse Links G & H ( W/Ammeter) In Harness, RH Side Of Dash Panel Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Locations Multiple Junction Connector: Locations LH Side Of Dash Panel Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Power and Ground Distribution > Power Protection Relay > Component Information > Locations Power Protection Relay: Locations In Engine Compartment On LH Fender Apron Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power Protection Relay > Component Information > Locations Power Protection Relay: Locations In Engine Compartment On LH Fender Apron Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull Alignment: Customer Interest Steering - Drift/Pull Article No. 85-19-15 STEERING - DRIFT/PULL CASTER SPLIT ADJUSTMENT LIGHT TRUCK 1980-86 F250-350 4x2; 1976-86 E100-350 A side-to-side front wheel caster difference greater than 3/4 degree can contribute to a vehicle drift or pull in the direction of the side with less caster. The service kit (E5TZ-3K064-A) can be used to increase the front wheel caster angle on either or both wheels to balance the caster split to correct a vehicle drift/pull concern. The kit contains complete parts and instructions needed to modify the front radius arm and mount a metal cam on the bottom flange of the radius arm. The kit can increase caster from 1/2 degree to 3 degrees, in 1/2 degree increments. It is not designed to decrease caster. To increase front wheel caster angle of subject vehicles and/or to balance a caster split, the following procedure is suggested: 1. Remove the radius arm from the vehicle as shown in Section 14-21 of the Reference Shop Manual and choose the appropriate paper template applicable to the vehicle model. Figure 8 - POSITIONING TEMPLATE TO LOWER FLANGE OF RADIUS ARM 2. Locate the template (3B474) on the bottom flange of the radius arm. Refer to Figure 8 for a typical arm modification for the right hand radius arm. One template per vehicle model is used to modify both the right and left hand radius arms. When modifying the right hand arm, position the Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 2622 template with the printed side downward. The template locates off of one of two existing holes in the radius arm. The E100-350 template is shaped to match the contours of the radius arm. Figure 9 - HOLE DRILLING INSTRUCTIONS - CAM ATTACHMENT TO LOWER FLANGE RADIUS ARM 3. With template secure, make a punch mark at the center of the small hole inside the printed circle. Scribe the slot printed/cut-out on the template and die-grind out the slot at the axle-attaching hole the same size as the slot in the template and de-burr the surface avoiding rounding the edges of the slot. Refer to Figure 9. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 2623 Figure 10 - ATTACHMENT OF ADJUSTING CAM TO RADIUS ARM 4. Drill a 0.228 inch diameter hole at the punch mark. Use this hole to mount the adjusting cam with the 1/4-20 self-tapping screw supplied. Refer to Figure 10. 5. Figure 10 shows a typical cam installation. Each hole in the cam represents a 1/2 degree caster increase. A caster increase of approximately 2 degrees for the E100-350, for example, will be obtained by mounting the cam with the selftapping screw in the No. 2 hole of the cam to the lower flange of the radius arm. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 2624 Figure 11 - TYPICAL INSTALLATION - FRONT AND RADIUS ARM 6. Figure 11 shows a typical vehicle installation. TORQUE BOLT "A" AND NUT "B" TO 270-330 FT. LBS. When increasing caster 2 degrees or more, the ears of the radius arm should be bent upward slightly to help install and seat the axles. Do not use heat to bend. 7. Reset front wheel toe after installation is complete. AFTER THE DESIRED ALIGNMENT IS ASSURED THE CAM MUST BE WELDED TO THE ARM ARC WELD ONE INCH MINIMUM LENGTH ALONG TWO SIDES OF THE CAM. NOTE: The metal adjusting cam plate has a Ford logo stamped on it to identify it for E100- 150 and F250-350 4x2 vehicles only on vehicles with a front stabilizer bar. The bar mounting bracket may be reworked to provide clearance for the self-tapping screw. Do not use parts from kit E4TZ3K064-A on these vehicles. PART NUMBER PART NAME CLASS E5TZ-3K064-A Kit Caster Adjustment C OTHER APPLICABLE ARTICLES: 85-13-12 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3360B85L TIME: Left - F Series: 2.4 Hrs. Econoline: 2.8 Hrs. OPERATION: SP3360B85R TIME: Right - F Series: 2.4 Hrs. Econoline: 2.8 Hrs. OPERATION: SP3360B85T TIME: Both - F Series: 3.8 Hrs. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 2625 Econoline: 4.6 Hrs. OPERATION: 3001A TIME: 0.5 Hr. - Check caster camber and toe-in DLR. CODING: Basic Part No. 3A360 - Code: 36 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Customer Interest for Alignment: > 851916 > Sep > 85 > Tires - Front Outside Edge Wear Alignment: Customer Interest Tires - Front Outside Edge Wear Article No. 85-19-16 TIRE WEAR - FRONT - OUTSIDE EDGE LIGHT TRUCK 1976-86 E100-150 Outboard shoulder wear, predominantly in lightly loaded city-delivery type use, is aggravated by excessive positive wheel camber in turning. The caster adjustment kit described in TSB 85-19-15 can be used to increase caster of either wheel up to 3 degrees in 1/2 degree increments. The kit contains complete instructions for modifying the front radius arms and mounting a metal adjusting cam to the bottom flange of each radius arm. Cams must be arc-welded a minimum of one inch along two sides of the cam to the lower flange of the radius arm. Increasing caster the full 3 degrees effectively reduces camber of the outboard wheel in a turn 1.5 degrees. Increasing caster more than 3 degrees is not recommended since this may cause complaints of wheel shimmy and/or excessive steering efforts. Also, caster should not be increased on vehicles built since April 1, 1984. These vehicles have the 3 degree caster increase already built into the axles which have axle part numbers E4UA-6-BA and E4UA-7-BA embossed on the face of each axle. Three other significant factors may also contribute to outboard shoulder wear. They are excessive toe-in (generally greater than 5/32 inch), excessive cornering speeds, and low tire pressure. After any adjustments to front end alignment, toe should be adjusted to zero. On vehicles subject to extensive city-delivery use, toe may be set up to 1/16 inch toe-out for optimum tire life. PART NUMBER PART NAME CLASS E5TZ-3K064-A Kit Caster Adjustment C OTHER APPLICABLE ARTICLES: 85-19-15 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3360B85T TIME: 4.6 Hrs. OPERATION: 3001A TIME: 0.5 Hr. - Check caster camber and toe-in DLR. CODING: Basic Part No. 3A360 - Code: 36 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull Alignment: All Technical Service Bulletins Steering - Drift/Pull Article No. 85-19-15 STEERING - DRIFT/PULL CASTER SPLIT ADJUSTMENT LIGHT TRUCK 1980-86 F250-350 4x2; 1976-86 E100-350 A side-to-side front wheel caster difference greater than 3/4 degree can contribute to a vehicle drift or pull in the direction of the side with less caster. The service kit (E5TZ-3K064-A) can be used to increase the front wheel caster angle on either or both wheels to balance the caster split to correct a vehicle drift/pull concern. The kit contains complete parts and instructions needed to modify the front radius arm and mount a metal cam on the bottom flange of the radius arm. The kit can increase caster from 1/2 degree to 3 degrees, in 1/2 degree increments. It is not designed to decrease caster. To increase front wheel caster angle of subject vehicles and/or to balance a caster split, the following procedure is suggested: 1. Remove the radius arm from the vehicle as shown in Section 14-21 of the Reference Shop Manual and choose the appropriate paper template applicable to the vehicle model. Figure 8 - POSITIONING TEMPLATE TO LOWER FLANGE OF RADIUS ARM 2. Locate the template (3B474) on the bottom flange of the radius arm. Refer to Figure 8 for a typical arm modification for the right hand radius arm. One template per vehicle model is used to modify both the right and left hand radius arms. When modifying the right hand arm, position the Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 2635 template with the printed side downward. The template locates off of one of two existing holes in the radius arm. The E100-350 template is shaped to match the contours of the radius arm. Figure 9 - HOLE DRILLING INSTRUCTIONS - CAM ATTACHMENT TO LOWER FLANGE RADIUS ARM 3. With template secure, make a punch mark at the center of the small hole inside the printed circle. Scribe the slot printed/cut-out on the template and die-grind out the slot at the axle-attaching hole the same size as the slot in the template and de-burr the surface avoiding rounding the edges of the slot. Refer to Figure 9. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 2636 Figure 10 - ATTACHMENT OF ADJUSTING CAM TO RADIUS ARM 4. Drill a 0.228 inch diameter hole at the punch mark. Use this hole to mount the adjusting cam with the 1/4-20 self-tapping screw supplied. Refer to Figure 10. 5. Figure 10 shows a typical cam installation. Each hole in the cam represents a 1/2 degree caster increase. A caster increase of approximately 2 degrees for the E100-350, for example, will be obtained by mounting the cam with the selftapping screw in the No. 2 hole of the cam to the lower flange of the radius arm. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 2637 Figure 11 - TYPICAL INSTALLATION - FRONT AND RADIUS ARM 6. Figure 11 shows a typical vehicle installation. TORQUE BOLT "A" AND NUT "B" TO 270-330 FT. LBS. When increasing caster 2 degrees or more, the ears of the radius arm should be bent upward slightly to help install and seat the axles. Do not use heat to bend. 7. Reset front wheel toe after installation is complete. AFTER THE DESIRED ALIGNMENT IS ASSURED THE CAM MUST BE WELDED TO THE ARM ARC WELD ONE INCH MINIMUM LENGTH ALONG TWO SIDES OF THE CAM. NOTE: The metal adjusting cam plate has a Ford logo stamped on it to identify it for E100- 150 and F250-350 4x2 vehicles only on vehicles with a front stabilizer bar. The bar mounting bracket may be reworked to provide clearance for the self-tapping screw. Do not use parts from kit E4TZ3K064-A on these vehicles. PART NUMBER PART NAME CLASS E5TZ-3K064-A Kit Caster Adjustment C OTHER APPLICABLE ARTICLES: 85-13-12 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3360B85L TIME: Left - F Series: 2.4 Hrs. Econoline: 2.8 Hrs. OPERATION: SP3360B85R TIME: Right - F Series: 2.4 Hrs. Econoline: 2.8 Hrs. OPERATION: SP3360B85T TIME: Both - F Series: 3.8 Hrs. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 851915 > Sep > 85 > Steering - Drift/Pull > Page 2638 Econoline: 4.6 Hrs. OPERATION: 3001A TIME: 0.5 Hr. - Check caster camber and toe-in DLR. CODING: Basic Part No. 3A360 - Code: 36 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > 851916 > Sep > 85 > Tires - Front Outside Edge Wear Alignment: All Technical Service Bulletins Tires - Front Outside Edge Wear Article No. 85-19-16 TIRE WEAR - FRONT - OUTSIDE EDGE LIGHT TRUCK 1976-86 E100-150 Outboard shoulder wear, predominantly in lightly loaded city-delivery type use, is aggravated by excessive positive wheel camber in turning. The caster adjustment kit described in TSB 85-19-15 can be used to increase caster of either wheel up to 3 degrees in 1/2 degree increments. The kit contains complete instructions for modifying the front radius arms and mounting a metal adjusting cam to the bottom flange of each radius arm. Cams must be arc-welded a minimum of one inch along two sides of the cam to the lower flange of the radius arm. Increasing caster the full 3 degrees effectively reduces camber of the outboard wheel in a turn 1.5 degrees. Increasing caster more than 3 degrees is not recommended since this may cause complaints of wheel shimmy and/or excessive steering efforts. Also, caster should not be increased on vehicles built since April 1, 1984. These vehicles have the 3 degree caster increase already built into the axles which have axle part numbers E4UA-6-BA and E4UA-7-BA embossed on the face of each axle. Three other significant factors may also contribute to outboard shoulder wear. They are excessive toe-in (generally greater than 5/32 inch), excessive cornering speeds, and low tire pressure. After any adjustments to front end alignment, toe should be adjusted to zero. On vehicles subject to extensive city-delivery use, toe may be set up to 1/16 inch toe-out for optimum tire life. PART NUMBER PART NAME CLASS E5TZ-3K064-A Kit Caster Adjustment C OTHER APPLICABLE ARTICLES: 85-19-15 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3360B85T TIME: 4.6 Hrs. OPERATION: 3001A TIME: 0.5 Hr. - Check caster camber and toe-in DLR. CODING: Basic Part No. 3A360 - Code: 36 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 2643 Alignment: By Symptom Technical Service Bulletin # 851916 Date: 850901 Tires - Front Outside Edge Wear Article No. 85-19-16 TIRE WEAR - FRONT - OUTSIDE EDGE LIGHT TRUCK 1976-86 E100-150 Outboard shoulder wear, predominantly in lightly loaded city-delivery type use, is aggravated by excessive positive wheel camber in turning. The caster adjustment kit described in TSB 85-19-15 can be used to increase caster of either wheel up to 3 degrees in 1/2 degree increments. The kit contains complete instructions for modifying the front radius arms and mounting a metal adjusting cam to the bottom flange of each radius arm. Cams must be arc-welded a minimum of one inch along two sides of the cam to the lower flange of the radius arm. Increasing caster the full 3 degrees effectively reduces camber of the outboard wheel in a turn 1.5 degrees. Increasing caster more than 3 degrees is not recommended since this may cause complaints of wheel shimmy and/or excessive steering efforts. Also, caster should not be increased on vehicles built since April 1, 1984. These vehicles have the 3 degree caster increase already built into the axles which have axle part numbers E4UA-6-BA and E4UA-7-BA embossed on the face of each axle. Three other significant factors may also contribute to outboard shoulder wear. They are excessive toe-in (generally greater than 5/32 inch), excessive cornering speeds, and low tire pressure. After any adjustments to front end alignment, toe should be adjusted to zero. On vehicles subject to extensive city-delivery use, toe may be set up to 1/16 inch toe-out for optimum tire life. PART NUMBER PART NAME CLASS E5TZ-3K064-A Kit Caster Adjustment C OTHER APPLICABLE ARTICLES: 85-19-15 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3360B85T TIME: 4.6 Hrs. OPERATION: 3001A TIME: 0.5 Hr. - Check caster camber and toe-in DLR. CODING: Basic Part No. 3A360 - Code: 36 Technical Service Bulletin # 851915 Date: 850926 Steering - Drift/Pull Article No. 85-19-15 STEERING - DRIFT/PULL CASTER SPLIT ADJUSTMENT LIGHT TRUCK 1980-86 F250-350 4x2; 1976-86 E100-350 A side-to-side front wheel caster difference greater than 3/4 degree can contribute to a vehicle drift or pull in the direction of the side with less caster. The service kit (E5TZ-3K064-A) can be used to increase the front wheel caster angle on either or both wheels to balance the caster split to correct a vehicle drift/pull concern. The kit contains complete parts and instructions needed to modify the front radius arm and mount a metal cam on the bottom flange of the radius arm. The kit can increase caster from 1/2 degree to 3 degrees, in 1/2 degree increments. It is not designed to decrease caster. To increase front wheel caster angle of subject vehicles and/or to balance a caster split, the following procedure is suggested: 1. Remove the radius arm from the vehicle as shown in Section 14-21 of the Reference Shop Manual and choose the appropriate paper template applicable to the vehicle model. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 2644 Figure 8 - POSITIONING TEMPLATE TO LOWER FLANGE OF RADIUS ARM 2. Locate the template (3B474) on the bottom flange of the radius arm. Refer to Figure 8 for a typical arm modification for the right hand radius arm. One template per vehicle model is used to modify both the right and left hand radius arms. When modifying the right hand arm, position the template with the printed side downward. The template locates off of one of two existing holes in the radius arm. The E100-350 template is shaped to match the contours of the radius arm. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 2645 Figure 9 - HOLE DRILLING INSTRUCTIONS - CAM ATTACHMENT TO LOWER FLANGE RADIUS ARM 3. With template secure, make a punch mark at the center of the small hole inside the printed circle. Scribe the slot printed/cut-out on the template and die-grind out the slot at the axle-attaching hole the same size as the slot in the template and de-burr the surface avoiding rounding the edges of the slot. Refer to Figure 9. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 2646 Figure 10 - ATTACHMENT OF ADJUSTING CAM TO RADIUS ARM 4. Drill a 0.228 inch diameter hole at the punch mark. Use this hole to mount the adjusting cam with the 1/4-20 self-tapping screw supplied. Refer to Figure 10. 5. Figure 10 shows a typical cam installation. Each hole in the cam represents a 1/2 degree caster increase. A caster increase of approximately 2 degrees for the E100-350, for example, will be obtained by mounting the cam with the selftapping screw in the No. 2 hole of the cam to the lower flange of the radius arm. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 2647 Figure 11 - TYPICAL INSTALLATION - FRONT AND RADIUS ARM 6. Figure 11 shows a typical vehicle installation. TORQUE BOLT "A" AND NUT "B" TO 270-330 FT. LBS. When increasing caster 2 degrees or more, the ears of the radius arm should be bent upward slightly to help install and seat the axles. Do not use heat to bend. 7. Reset front wheel toe after installation is complete. AFTER THE DESIRED ALIGNMENT IS ASSURED THE CAM MUST BE WELDED TO THE ARM ARC WELD ONE INCH MINIMUM LENGTH ALONG TWO SIDES OF THE CAM. NOTE: The metal adjusting cam plate has a Ford logo stamped on it to identify it for E100- 150 and F250-350 4x2 vehicles only on vehicles with a front stabilizer bar. The bar mounting bracket may be reworked to provide clearance for the self-tapping screw. Do not use parts from kit E4TZ3K064-A on these vehicles. PART NUMBER PART NAME CLASS E5TZ-3K064-A Kit Caster Adjustment C OTHER APPLICABLE ARTICLES: 85-13-12 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3360B85L TIME: Left - F Series: 2.4 Hrs. Econoline: 2.8 Hrs. OPERATION: SP3360B85R TIME: Right - F Series: 2.4 Hrs. Econoline: 2.8 Hrs. OPERATION: SP3360B85T TIME: Both - F Series: 3.8 Hrs. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 2648 Econoline: 4.6 Hrs. OPERATION: 3001A TIME: 0.5 Hr. - Check caster camber and toe-in DLR. CODING: Basic Part No. 3A360 - Code: 36 Technical Service Bulletin # 851916 Date: 850901 Tires - Front Outside Edge Wear Article No. 85-19-16 TIRE WEAR - FRONT - OUTSIDE EDGE LIGHT TRUCK 1976-86 E100-150 Outboard shoulder wear, predominantly in lightly loaded city-delivery type use, is aggravated by excessive positive wheel camber in turning. The caster adjustment kit described in TSB 85-19-15 can be used to increase caster of either wheel up to 3 degrees in 1/2 degree increments. The kit contains complete instructions for modifying the front radius arms and mounting a metal adjusting cam to the bottom flange of each radius arm. Cams must be arc-welded a minimum of one inch along two sides of the cam to the lower flange of the radius arm. Increasing caster the full 3 degrees effectively reduces camber of the outboard wheel in a turn 1.5 degrees. Increasing caster more than 3 degrees is not recommended since this may cause complaints of wheel shimmy and/or excessive steering efforts. Also, caster should not be increased on vehicles built since April 1, 1984. These vehicles have the 3 degree caster increase already built into the axles which have axle part numbers E4UA-6-BA and E4UA-7-BA embossed on the face of each axle. Three other significant factors may also contribute to outboard shoulder wear. They are excessive toe-in (generally greater than 5/32 inch), excessive cornering speeds, and low tire pressure. After any adjustments to front end alignment, toe should be adjusted to zero. On vehicles subject to extensive city-delivery use, toe may be set up to 1/16 inch toe-out for optimum tire life. PART NUMBER PART NAME CLASS E5TZ-3K064-A Kit Caster Adjustment C OTHER APPLICABLE ARTICLES: 85-19-15 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3360B85T TIME: 4.6 Hrs. OPERATION: 3001A TIME: 0.5 Hr. - Check caster camber and toe-in DLR. CODING: Basic Part No. 3A360 - Code: 36 Technical Service Bulletin # 851915 Date: 850926 Steering - Drift/Pull Article No. 85-19-15 STEERING - DRIFT/PULL CASTER SPLIT ADJUSTMENT LIGHT TRUCK 1980-86 F250-350 4x2; 1976-86 E100-350 A side-to-side front wheel caster difference greater than 3/4 degree can contribute to a vehicle drift or pull in the direction of the side with less caster. The service kit (E5TZ-3K064-A) can be used to increase the front wheel caster angle on either or both wheels to balance the caster split to correct a vehicle drift/pull concern. The kit contains complete parts and instructions needed to modify the front radius arm and mount a metal cam on the bottom flange of the radius arm. The kit can increase caster from 1/2 degree to 3 degrees, in 1/2 degree increments. It is not designed to decrease caster. To increase front wheel caster angle of subject vehicles and/or to balance a caster split, the following procedure is suggested: 1. Remove the radius arm from the vehicle as shown in Section 14-21 of the Reference Shop Manual and choose the appropriate paper template applicable to the vehicle model. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 2649 Figure 8 - POSITIONING TEMPLATE TO LOWER FLANGE OF RADIUS ARM 2. Locate the template (3B474) on the bottom flange of the radius arm. Refer to Figure 8 for a typical arm modification for the right hand radius arm. One template per vehicle model is used to modify both the right and left hand radius arms. When modifying the right hand arm, position the template with the printed side downward. The template locates off of one of two existing holes in the radius arm. The E100-350 template is shaped to match the contours of the radius arm. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 2650 Figure 9 - HOLE DRILLING INSTRUCTIONS - CAM ATTACHMENT TO LOWER FLANGE RADIUS ARM 3. With template secure, make a punch mark at the center of the small hole inside the printed circle. Scribe the slot printed/cut-out on the template and die-grind out the slot at the axle-attaching hole the same size as the slot in the template and de-burr the surface avoiding rounding the edges of the slot. Refer to Figure 9. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 2651 Figure 10 - ATTACHMENT OF ADJUSTING CAM TO RADIUS ARM 4. Drill a 0.228 inch diameter hole at the punch mark. Use this hole to mount the adjusting cam with the 1/4-20 self-tapping screw supplied. Refer to Figure 10. 5. Figure 10 shows a typical cam installation. Each hole in the cam represents a 1/2 degree caster increase. A caster increase of approximately 2 degrees for the E100-350, for example, will be obtained by mounting the cam with the selftapping screw in the No. 2 hole of the cam to the lower flange of the radius arm. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 2652 Figure 11 - TYPICAL INSTALLATION - FRONT AND RADIUS ARM 6. Figure 11 shows a typical vehicle installation. TORQUE BOLT "A" AND NUT "B" TO 270-330 FT. LBS. When increasing caster 2 degrees or more, the ears of the radius arm should be bent upward slightly to help install and seat the axles. Do not use heat to bend. 7. Reset front wheel toe after installation is complete. AFTER THE DESIRED ALIGNMENT IS ASSURED THE CAM MUST BE WELDED TO THE ARM ARC WELD ONE INCH MINIMUM LENGTH ALONG TWO SIDES OF THE CAM. NOTE: The metal adjusting cam plate has a Ford logo stamped on it to identify it for E100- 150 and F250-350 4x2 vehicles only on vehicles with a front stabilizer bar. The bar mounting bracket may be reworked to provide clearance for the self-tapping screw. Do not use parts from kit E4TZ3K064-A on these vehicles. PART NUMBER PART NAME CLASS E5TZ-3K064-A Kit Caster Adjustment C OTHER APPLICABLE ARTICLES: 85-13-12 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3360B85L TIME: Left - F Series: 2.4 Hrs. Econoline: 2.8 Hrs. OPERATION: SP3360B85R TIME: Right - F Series: 2.4 Hrs. Econoline: 2.8 Hrs. OPERATION: SP3360B85T TIME: Both - F Series: 3.8 Hrs. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > All Technical Service Bulletins for Alignment: > Page 2653 Econoline: 4.6 Hrs. OPERATION: 3001A TIME: 0.5 Hr. - Check caster camber and toe-in DLR. CODING: Basic Part No. 3A360 - Code: 36 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 2654 Alignment: Specifications Camber Caster Toe Ride Height 3.25-3.50 in -1 3/4 to -1/4 deg +6 1/4 to +8 deg 1/8 in 3.50-3.75 in -1 1/2 to + 1/4 deg +5 3/4 to +7 1/4 deg 1/8 in 4.00-4.25 in -1/2 to + 1 1/4 deg +4 1/2 to +5 3/4 deg 1/8 in 4.25-4.50 in 0 to + 1 3/4 deg +4 to +5 1/4 deg 1/8 in 4.50-4.75 in + 1/2 to +2 1/4 deg +3 1/4 to +4 1/2 deg 1/8 in 5.00-5.25 in +1 1/2 to + 3 1/4 deg +2 to +3 1/4 deg 1/8 in 5.25-5.50 in +2 to +3 3/4 deg +1 1/2 to +2 3/4 deg 1/8 in Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 2655 Alignment: Service and Repair Fig. 1 Measuring Ride Height Fig. 7 Measuring riding height. 1980---85 F-100---350 & Bronco Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Page 2656 Fig. 8 Measuring Riding Height Prior to checking caster and camber, ensure vehicle front ride height is within {1/8} inch side to side 1980-87 E-100-350. On 1980-87 F-100-350 models, the left side ride height should be within 0-{3/8} inch higher than the right side ride height. On 1980-87 F-150-350 (4x4) and Bronco, the front ride heights should be within {3/16} inch side to side. Refer to Figs. 6, 7 and 8. If the vehicle ride heights are not within specifications, redistribute load on loaded vehicles or slightly load empty vehicles on one side. If the ride heights cannot be brought within specifications, verify correct spring installation. The ride height variations stated, are for checking purposes only. The vehicle does not have to operate within these specifications. Check and correct as necessary all tire inflation pressures, then check front tires for the same size, ply rating and load range. Check front wheel bearings and adjust as necessary. If all the above checks have been made, check wheel alignment with suitable alignment equipment. Using the ride heights obtained earlier, compare caster and camber readings to those listed in the ``Wheel Alignment Specifications Chart''. If the caster and camber angles exceed the specifications, inspect front end for damaged suspension components. Replace as necessary. Alignment equipment indicates a true reading only when the vehicle's frame is horizontal. Therefore, if the frame is not level (due to tire, spring or load differences), the caster angle reading must be modified to compensate for the frame angles. If the front is higher than the rear, subtract the amount of angle from the reading. If the front is lower than the rear, add the angle. To check frame angle, use a spirit protractor, and take the frame angle measurement on the lower frame flange at the flat area immediately adjacent to the rear spring front hanger. 1980-85 4 X 2 MODELS EXC. 1982-85 F-100-350 W/BALL JOINTS The camber and caster angles are designed into the front end and are not adjustable. TOE-IN, ADJUST Check the steering wheel spoke position when the front wheels are in the straight ahead position. If the spokes are not in the normal position, they can be adjusted while toe-in is being adjusted. 1. Loosen clamp bolts on each tie rod end sleeve. 2. Adjust toe-in. If steering wheel spokes are in their normal position, lengthen or shorten both rods equally to obtain correct toe-in. If spokes are not in normal position, make necessary rod adjustments to obtain correct toe-in and steering wheel spoke alignment. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > Customer Interest for Center Link: > 881414 > Jul > 88 > Steering - Unequal Left and Right Turn Angles Center Link: Customer Interest Steering - Unequal Left and Right Turn Angles ^ STEERING - UNEQUAL LEFT AND RIGHT TURN ANGLES - VEHICLES BUILT BEFORE 2/22/88 ^ STEERING - OFF CENTER STEERING GEAR AND WIDE CENTER FEEL - VEHICLES BUILT BEFORE 2/22/88 Article No. 88-14-14 LIGHT TRUCK: 1975-88 E SERIES ISSUE: Unequal left hand and right hand turn angles, wide center steering wheel feel and a variance in steering wheel rotation from the straight-ahead position to full right turn versus the straight-ahead position to full left turn may be caused by tolerance stack-ups and only one (1) adjusting sleeve for toe-in setting which allows the steering maximum travel to be regulated by steering gear travel rather than the axle spindle steering stops. ACTION: To correct this, install a new design drag link with an adjusting sleeve. Refer to the following service procedure. Refer to the steering drag link application chart on page 32 of this TSB for the correct service parts. FIGURE 12 1. Remove cotter pin and nut from both drag link ball studs and the tie rod stud at the drag link. Refer to Figure 12. 2. Remove the tie rod ball stud from the drag link using a tie rod end remover. 3. Remove both drag link ball studs from the pitman arm and right hand spindle. 4. Remove the steering wheel from the tapered section of the steering column shaft, Refer to the Light Truck Shop Manual, Volume A, Section 13-06 for detailed service procedures. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > Customer Interest for Center Link: > 881414 > Jul > 88 > Steering - Unequal Left and Right Turn Angles > Page 2666 5. Place the wheel loosely on the shaft so that it can be easily removed by hand later. 6. Turn the steering wheel to the right stop. 7. Turn the steering wheel to the left stop while counting the number of turns. 8. Turn the wheel to the right one-half of the number of turns counted in Step 7. The steering gear is now centered. 9. Without rotating the steering column, remove the steering wheel from the column and reinstall it so that the clear vision is set at 0 degrees. NOTE: THE STEERING COLUMN MUST NOT MOVE DURING THIS OPERATION OR THE STEERING GEAR WILL BE OFF CENTER. 10. Repeat Steps 6, 7 and 8 to make sure the steering gear is centered. 11. Tighten steering wheel retaining to the torque specification listed in the Light Truck Shop Manual, Volume A, Section 13-06. 12. Assemble the new drag link, tie rod end and adjusting sleeve. 13. Adjust the length of the drag link assembly so that it is about the same as the length of the old drag link. 14. Install the new drag link. Refer to the Light Truck Shop Manual, Volume A, Section 13-24 for service details. NOTE: THE WHEELS MUST BE IN THE STRAIGHT-AHEAD POSITION AND THE STUDS SEATED IN THE TAPERED HOLE PRIOR TO TIGHTENING THE NUTS SO THAT THE RUBBER BALL SOCKETS WILL NOT BE PRELOADED AND CAUSE A DRIFT CONDITION. 15. Check and adjust toe. Refer to the Light Truck Shop Manual, Volume A, Section 14-01 for front end alignment specifications and procedures. NOTE: USE THE F SERIES PROCEDURE SINCE THE SYSTEM NOW HAS TWO (2) ADJUSTING SLEEVES. 16. After toe is set, be sure to position the two (2) clamp bolts on the drag link adjusting sleeve BELOW the linkage. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic OPERATION: 881414A Warranty Coverage TIME: 1.2 Hrs. DLR. CODING: Basic Part No. 3A131 Condition Code: 37 PART NUMBER PART NAME CLASS E8UZ-3A131-A Socket - Steering Drag B Link Arm E8UZ-3A131-B Socket - Steering Drag C Link Arm E8UZ-3304-A Socket - Steering Drag B Link Pitman Arm E8UZ-3304-B Socket - Steering Drag C Link Pitman Arm D2TZ-3281-A Tube - Adjuster AG E7TZ-3281-A Tube - Adjuster C Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Center Link: > 881414 > Jul > 88 > Steering - Unequal Left and Right Turn Angles Center Link: All Technical Service Bulletins Steering - Unequal Left and Right Turn Angles ^ STEERING - UNEQUAL LEFT AND RIGHT TURN ANGLES - VEHICLES BUILT BEFORE 2/22/88 ^ STEERING - OFF CENTER STEERING GEAR AND WIDE CENTER FEEL - VEHICLES BUILT BEFORE 2/22/88 Article No. 88-14-14 LIGHT TRUCK: 1975-88 E SERIES ISSUE: Unequal left hand and right hand turn angles, wide center steering wheel feel and a variance in steering wheel rotation from the straight-ahead position to full right turn versus the straight-ahead position to full left turn may be caused by tolerance stack-ups and only one (1) adjusting sleeve for toe-in setting which allows the steering maximum travel to be regulated by steering gear travel rather than the axle spindle steering stops. ACTION: To correct this, install a new design drag link with an adjusting sleeve. Refer to the following service procedure. Refer to the steering drag link application chart on page 32 of this TSB for the correct service parts. FIGURE 12 1. Remove cotter pin and nut from both drag link ball studs and the tie rod stud at the drag link. Refer to Figure 12. 2. Remove the tie rod ball stud from the drag link using a tie rod end remover. 3. Remove both drag link ball studs from the pitman arm and right hand spindle. 4. Remove the steering wheel from the tapered section of the steering column shaft, Refer to the Light Truck Shop Manual, Volume A, Section 13-06 for detailed service procedures. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Steering > Center Link > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Center Link: > 881414 > Jul > 88 > Steering - Unequal Left and Right Turn Angles > Page 2672 5. Place the wheel loosely on the shaft so that it can be easily removed by hand later. 6. Turn the steering wheel to the right stop. 7. Turn the steering wheel to the left stop while counting the number of turns. 8. Turn the wheel to the right one-half of the number of turns counted in Step 7. The steering gear is now centered. 9. Without rotating the steering column, remove the steering wheel from the column and reinstall it so that the clear vision is set at 0 degrees. NOTE: THE STEERING COLUMN MUST NOT MOVE DURING THIS OPERATION OR THE STEERING GEAR WILL BE OFF CENTER. 10. Repeat Steps 6, 7 and 8 to make sure the steering gear is centered. 11. Tighten steering wheel retaining to the torque specification listed in the Light Truck Shop Manual, Volume A, Section 13-06. 12. Assemble the new drag link, tie rod end and adjusting sleeve. 13. Adjust the length of the drag link assembly so that it is about the same as the length of the old drag link. 14. Install the new drag link. Refer to the Light Truck Shop Manual, Volume A, Section 13-24 for service details. NOTE: THE WHEELS MUST BE IN THE STRAIGHT-AHEAD POSITION AND THE STUDS SEATED IN THE TAPERED HOLE PRIOR TO TIGHTENING THE NUTS SO THAT THE RUBBER BALL SOCKETS WILL NOT BE PRELOADED AND CAUSE A DRIFT CONDITION. 15. Check and adjust toe. Refer to the Light Truck Shop Manual, Volume A, Section 14-01 for front end alignment specifications and procedures. NOTE: USE THE F SERIES PROCEDURE SINCE THE SYSTEM NOW HAS TWO (2) ADJUSTING SLEEVES. 16. After toe is set, be sure to position the two (2) clamp bolts on the drag link adjusting sleeve BELOW the linkage. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic OPERATION: 881414A Warranty Coverage TIME: 1.2 Hrs. DLR. CODING: Basic Part No. 3A131 Condition Code: 37 PART NUMBER PART NAME CLASS E8UZ-3A131-A Socket - Steering Drag B Link Arm E8UZ-3A131-B Socket - Steering Drag C Link Arm E8UZ-3304-A Socket - Steering Drag B Link Pitman Arm E8UZ-3304-B Socket - Steering Drag C Link Pitman Arm D2TZ-3281-A Tube - Adjuster AG E7TZ-3281-A Tube - Adjuster C Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Service and Repair Front Steering Knuckle: Service and Repair Spindle REMOVE 1. Raise the front of the vehicle and install safety stands. 2. Remove the wheel and tire assembly. 3. Remove the caliper assembly from the rotor and hold it out of the way with wire. 4. Remove the dust cap, cotter pin, nut retainer, nut, washer, and outer bearing, and remove the rotor from the spindle. 5. Remove inner bearing cone and seal. Discard the seal. 6. Remove brake dust shield. 7. Disconnect the steering linkage from the spindle arm by removing the cotter pin and nut, and then removing the tie rod end from the spindle arm with tie Rod End Remover, TOOL-3290-D or equivalent. 8. Remove the nut and lockwasher from the lock pin, and remove the lock pin. 9. Remove the upper and lower spindle pin plugs; then, drive the spindle pin out from the top of the axle and remove the spindle and thrust bearing. Remove the spindle pin seal and thrust bearing. INSTALL 1. Make sure the spindle pin hole in the axle is free of nicks, burrs, corrosion or foreign material. Clean up the bore as necessary and lightly coat the surface with a lithium-base grease, Long-Life Lubricant, C1AZ-19590-BA (ESA-M1C75-B) or equivalent. 2. Install a new spindle pin seal with the metal backing facing up towards the bushing into the spindle. Gently press seal into position, being careful not to distort the casing. 3. Install a new thrust bearing with the lip flange facing down towards the lower bushing. Press until the bearing is firmly seated against the surface of the spindle. 4. Lightly coat the bushing surfaces with grease and place the spindle in position on the axle. 5. Hold the spindle with thrust bearing in place tight against the axle and measure the space between the axle and the spindle at the top of the axle. If the vehicle uses shims, select the proper shims and install. 6. Install the spindle pin with the "T" stamped on one end towards the top, and the notch in the pin aligned with the lock pin hole in the axle. Insert the spindle pin through the bushings and axle from the top until the spindle pin notch and axle lock pin hole are in line. 7. Install the lock pin with the threads pointing forward and the wedge groove facing the spindle pin notch. Firmly drive the lock pin into position and mount the lockwasher and nut. Tighten the nut to 52-84 Nm (38-62 ft lb). 8. Install the spindle pin plugs into the threads at the top and bottom of the spindle. Tighten the plugs to 48-67 Nm (35-50 ft lb). 9. Lubricate the spindle pin and bushings with Long-Life Lubricant C1AZ-19590-BA (ESA-M1C75-B) or equivalent, through both fittings until grease is visible seeping past the upper seal at the top and from the thrust bearing slip joint at the bottom. If grease does not appear, recheck the installation procedure to correct the problem. Lack of adequate lubrication will result in rapid failure of the spindle components. 10. Install the dust shield. 11. Pack the inner and outer bearing cone with bearing grease. Use a bearing packer. If a bearing packer is unavailable, pack the bearing cone by hand working the grease through the cage behind the rollers. 12. Install the inner bearing cone and seal. Install the hub and rotor on the spindle. 13. Install the outer bearing cone, washer, and nut. Adjust bearing end play and install the nut retainer, cotter pin and dust cap. 14. Install the caliper. 15. Connect the steering tie rod and drag link (if equipped) to the spindle. Tighten the nut to specifications and advance the nut as required for installation of the cotter pin. 16. Install the wheel and tire assembly. 17. Lower the vehicle. 18. Check and, if necessary adjust the toe setting. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair Power Steering Bleeding: Service and Repair Four factors affect power operation of the steering system: fluid level and condition, drive belt tension, pump pressure and steering gear adjustment. These should always be checked before any major service operations are performed. Conditions such as, hard or loose steering, road shock or vibrations are not always due to steering gear or pump, but are often related instead to such factors as low tire pressure and front end alignment. These factors should be checked and corrected before any adjustment of the steering gear is made. CHECKING FLUID LEVEL 1. Run engine to normal operating temperature, then shut it off. Remove reservoir filler cap and check oil level on dipstick. Level should be up to ``Full'' mark on dipstick. 2. If level is low, add power steering fluid to proper level on dipstick and replace filler cap. When adding less than one pint of fluid, it is permissible to use automatic transmission fluid. When adding larger quantities or when making a complete fluid change, it is recommended that special power steering fluid be used. 3. When checking fluid level after system has been serviced, air must be bled from the system as outlined under ``Bleeding System.'' BLEEDING SYSTEM 1. With wheels turned all the way to the left, add the recommended fluid to the ``Add'' mark on dipstick. 2. Start engine. While running at fast idle, recheck fluid level and, if necessary, add fluid to the ``Add'' mark on dipstick. 3. Bleed system by turning wheels from side to side without hitting stops. Maintain fluid level just above internal pump casting. Fluid with air in it will have a light tan appearance. This air must be eliminated from fluid before normal steering action can be obtained. 4. Return wheels to center position and continue to run engine for two or three minutes, then shut it off. 5. Road test vehicle to make sure steering functions normally and is free from noise. 6. Recheck fluid level, making sure level is at the ``Full'' mark. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Technical Service Bulletins > Power Steering pump - Rotor and `C' Clip Changes Power Steering Pump: Technical Service Bulletins Power Steering pump - Rotor and `C' Clip Changes Article No. 83-10-6 STEERING - POWER - PUMP - FORD ROTOR AND "C" CLIP CHANGES FORD 1980 PINTO 1980-82 GRANADA, FORD 1980-83 MUSTANG, FAIRMONT, T-BIRD 1981-83 ESCORT 1982-83 EXP 1983 LTD, CROWN VICTORIA LINCOLN-MERCURY 1980 BOBCAT, MONARCH, VERSAILLES 1980-82 MERCURY 1980-83 CAPRI, ZEPHYR, COUGAR, XR7, LINCOLN, MARK 1981-83 LYNX 1982-83 LN7, CONTINENTAL 1983 MARQUIS, GRAND MARQUIS LIGHT TRUCKS 1980-83 F100, 150, 250, 350 1980-83 BRONCO 1983 RANGER The rotor identification mark for re-assembly and rotor retention "C" clip is changed. Figure 8 CII pumps built since August 1982 no longer have rotors with the small triangular detent on the counterbore to indicate that this is the up side when reassembling (Figure 8). When servicing a pump built since that time it is necessary to determine which side has the larger counterbore and face that side up. It is important that the larger counterbore be up or the "C" clip will not install properly on the shaft. Then it would be necessary to remove the rotor from the cam, turn it over and re-install the slippers and springs. Also, pumps built since February of 1983 have different rotor retention "C" clip (Figure 8). Either clip will fit on the shaft but the new clip is preferred. OTHER APPLICABLE ARTICLES: 83-6-7 WARRANTY STATUS: "INFORMATION ONLY" SPECIAL INSTRUCTIONS: Face larger rotor counterbore up when re-assembling. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation Power Steering Pump: Service and Repair Removal and Installation E-100-350 1. Disconnect pressure and return lines from pump. 2. Loosen belt tension adjusting bolt fully. 3. On models equipped with A/C, remove pump mounting bracket to A/C compressor mounting bracket attaching bolts. 4. On all models, remove pump and mounting brackets from vehicle. 5. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 2686 Power Steering Pump: Service and Repair Disassembly Fig. 1 Exploded view of Ford Model CII power steering pump Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 2687 Fig. 2 Positioning Pump In C-Clamp Fig. 2 Positioning Pump In C-Clamp 1. Remove pulley from pump. 2. Remove outlet fitting, flow control valve and flow control valve spring from pump, then remove reservoir, Fig. 1. 3. Place a suitable C-clamp in a vise. 4. Position lower support plate T78P-3733-A2 over pump rotor shaft. 5. Install upper compressor plate T78P-3733-A1 into upper portion of C-clamp. 6. While holding compressor tool, place pump assembly into C-clamp with rotor shaft facing downward, Fig. 2. 7. Tighten C-clamp until a slight bottoming of valve cover is observed. 8. Through small hole located on side of pump housing, insert a suitable drift and push inward on valve cover snap ring. While pushing inward on snap ring, place a screwdriver under snap ring edge and remove ring from housing, Fig. 3. 9. Loosen C-clamp and remove upper compressor plate T78P-3733-A2, then remove pump assembly. 10. Remove pump valve cover and O-ring. 11. Remove rotor shaft, upper plate, cam and rotor assembly and two dowel pins. 12. Remove lower plate and spring, by tapping housing on a flat surface. 13. Using a suitable screwdriver, remove rotor shaft seal. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 2688 Power Steering Pump: Service and Repair Assembly Fig. 1 Exploded view of Ford Model CII power steering pump Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 2689 Fig. 4 Installing Slipper Springs Fig. 5 Installing Slippers 1. Position rotor on rotor shaft splines with triangle detent on rotor counter bore facing upward. 2. Install snap ring into groove on end of rotor shaft, Fig. 1. 3. Position insert cam over rotor. Ensure recessed notch on insert cam is facing upward. 4. With rotor extended upward approximately half out of cam, insert spring into rotor picket, Fig. 4. 5. Use a slipper to compress spring, then install slipper with groove facing cam, Fig. 5. 6. Perform steps 4 and 5 on slipper cavity beneath opposite inlet recess. 7. While holding cam stationary, index rotor left or right one space and install another spring and slipper until all ten rotor cavities have been filled. Ensure rotor springs and slippers remain in position while turning. 8. Apply Loctite No. 242 or 271 adhesive or equivalent to outside diameter of seal and Lockquick NF or T primer or equivalent to seal bore in housing. Install rotor shaft seal using tool No. T78P-3733-A3. Using a plastic mallet, drive seal into bore until properly seated. 9. Position pump plate on flat surface with pulley side facing downward. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 2690 10. Install two dowel pins and spring into housing. Spring must be inserted with dished surface facing upward. 11. Lubricate inner and outer O-ring seals with power steering fluid, then install seals on lower pressure plate. 12. Install lower pressure plate into housing and over dowel pin with O-ring seals facing toward front of pump. Position assembly on C-clamp. Place tool No. T78P-3733-A3 into rotor shaft hole and press on lower plate lightly until it bottoms in pump housing. This will seat the outer O-ring seal. Upper Pressure Plate Installation Fig. 8 Installing Valve Cover Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 2691 Fig. 6 Assembling Cam, Slippers And Rotor 13. Install cam, rotor, rotor and slippers and rotor shaft assembly into pump housing over dowel pins. When installing assembly into pump housing,stepped holes must be used for dowel pins and notch in cam insert must be toward reservoir and approximately 180 degrees opposite square mounting lug on housing, Fig. 6. 14. Position upper pressure plate over dowel pins with recess directly over recessed notch on cam insert and approximately 180 degrees opposite square mounting lug, Fig. 7. 15. Lubricate O-ring seal with power steering fluid. Then, position O-ring on valve cover. Ensure plastic baffle is securely in position on valve cover. A coat of petroleum jelly may be used to hold baffle in position. 16. Insert valve cover over dowel pins. Ensure outlet fitting hole in valve cover is aligned with square mounting lug on housing, Fig. 8. 17. Place assembly in C-clamp and compress valve cover into pump housing until snap ring groove on housing is exposed. 18. Install valve cover snap ring in pump housing. Ensure snap ring ends are near access hole in pump housing. 19. Remove pump assembly from C-clamp. 20. Lubricate O-ring seal with power steering fluid, then place seal on pump housing. 21. Install reservoir on pump housing. 22. Install flow control valve and spring into valve cover. 23. Lubricate O-ring seals with power steering fluid, then place seals on outlet fitting. 24. Install outlet fitting on valve cover. Torque outlet fitting to 25---34 ft. lbs. Use care not to cock flow control valve when installing. Do not force valve forward otherwise damage to housing may result. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 2692 Power Steering Pump: Service and Repair Vane Type Pump W/ Integral Reservoir Disassembly Fig. 1 Vane type power steering pump w/integral reservoir disassembled (typical) Fig. 2 Removing end plate retaining ring Fig. 3 Removing flow control valve & spring Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 2693 Fig. 4 Thrust plate & rotor installed on driveshaft 1. Referring to Fig. 1, carefully mount pump in vise with soft jaws and remove reservoir cap. When clamping pump in vise, do not exert excessive force on front hub as this may distort drive shaft bushing in housing. 2. Remove rear pump mounting stud and O-ring seal, pressure union and O-ring seal. 3. Remove reservoir, and second pressure union O-ring seal. 4. Using a small punch, depress end plate retaining ring enough to allow removal from groove. Use the {1/8} inch diameter hole in housing, Fig. 2. Then remove retaining ring with screwdriver. 5. Remove end plate which is spring loaded and usually sits above housing level. If end plate sticks, a slight rocking action should free it. If rocking action fails to free plate, use a magnet. 6. Remove two pressure springs from pump housing. 7. Remove flow control valve and spring by inverting housing. Do not disassemble flow control valve as it is serviced as a unit and pre-set at the factory, Fig. 3. 8. Remove drive shaft key from slot in shaft. Then with end of shaft pointed downward, press down until shaft is free. 9. Turn assembly over and remove drive shaft and rotary group. 10. Remove rotor retaining ring from groove in drive shaft. Remove rotor and thrust plate from shaft, Fig. 4. 11. Remove and discard O-ring seals from pump housing. Remove driveshaft oil seal only if inspection shows necessity for replacement. Inspection 1. Clean all parts except the drive shaft oil seal in cleaning fluid. The seal will be damaged if immersed in cleaning fluid. 2. Check fit of vanes in slots of rotor for tightness or excessive looseness. Vanes must fit snugly but slide freely in slots in rotor. Tight fit of vanes in rotor can usually be corrected by thorough cleaning. Replace rotor if excessive looseness exists between rotor and vanes. Replace vanes if worn or scored. 3. Examine machined surfaces of pump ring for roughness or wear. Replace ring if roughness cannot be corrected with crocus cloth. 4. Inspect thrust plate, pressure plate and end plate for wear, scores or other damage. 5. Inspect pump housing for cracks or damage. Check housing for evidence of wear or scoring. 6. Check all springs for free length, distortion or collapsed coils. 7. Inspect located dowel pins for distortion. 8. Examine outer diameter of flow control valve for scoring or roughness. Slight damage may be cleaned up with crocus cloth. Check valve assembly for freedom of movement in bore of pump housing. 9. Check all oil passages in pump parts for obstruction. Use a piece of tag wire to clean out holes. 10. Check bushing in pump housing for wear or damage. Assembly Fig. 4 Thrust plate & rotor installed on driveshaft Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 2694 Fig. 5 Installing driveshaft assembly Fig. 6 Installing pump ring Fig. 7 Installing rotor vanes 1. Lubricate new O-ring seals with Vaseline and place in pump housing. 2. If drive shaft oil seal was removed during disassembly, lubricate new seal with Vaseline. Then install seal in pump body front hub, using a suitable seal driver. 3. Position thrust plate and rotor on drive shaft. Then install rotor retaining ring in groove of drive shaft, Fig. 4. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 2695 4. Place pump housing on work bench as shown in Fig. 5 and install two pump ring dowel pins in bore of housing. 5. Install drive shaft in housing, making sure shaft seats properly. 6. Install pump ring in housing over two dowel pins with rotation arrow on ring to rear of pump housing, Fig. 6.Arrow on outer edge of pump ring points in direction of pump rotation (counterclockwise when viewed from rear of pump). 7. Install rotor vanes in slots of pump rotor, with radius edge of vanes toward outside of rotor, Fig. 7. Fig. 8 Installing pressure plate Fig. 9 Installing pressure plate springs 8. Position pump housing on two wood blocks and push parts down into place as shown in Fig. 8. 9. Lubricate outside diameter and chamfer of pressure plate with Vaseline to insure against damage to O-ring seals in housing. Then install pressure plate in housing over dowel pins.Ported face of pressure plate goes toward pump ring, Fig. 8. 10. Using a 2{3/4} inch diameter sleeve to apply pressure to outer edge of pressure plate only, press pressure plate into seat. Pressure plate will travel about {1/16} inch to seat. Do not press or hammer on center of pressure plate as to do so will cause permanent distortion resulting in pump failure. 11. Install two pressure plate springs, one over each dowel pin in pump housing, Fig. 9. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 2696 Fig. 10 Installing end plate & retaining ring Fig. 11 Installing flow control valve & spring Fig. 12 Installing pressure union O-ring seal 12. Lubricate outside diameter and chamfer of end plate with Vaseline to insure against damage to O-ring seal in housing. Then press end plate into housing. While holding end plate down in housing, install end plate retaining ring. Be sure end plate is completely and solidly seated in groove of housing, Fig. 10. 13. Remove assembly from press and place on work bench. Install flow control spring and valve in bore of housing. Make sure hex head screw goes into housing bore, Fig. 11. 14. Position pressure union O-ring seal in bore of housing over flow control valve, Fig. 12. 15. Mount pump housing in vise with soft jaws and install reservoir. 16. Install pressure union and new O-ring seal in reservoir. Tighten union. 17. Install mounting stud and new O-ring seal in reservoir. Tighten stud. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 2697 18. Install drive shaft key in slot in shaft. Support shaft on opposite side while installing key. Install reservoir cap. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 2698 Power Steering Pump: Service and Repair Vane Type Pump, Less Integral Reservoir Fig. 1 Vane type power steering pump, less integral reservoir disassembled Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 2699 Fig. 2 Removal & installation of return tube, control valve, driveshaft, ball bearing assembly & driveshaft seal Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 2700 Fig. 3 Removal & installation of rotating group Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 2701 Fig. 4 Removal & installation of sleeve assembly Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service Precautions Steering Column: Service Precautions When the steering column is installed in the vehicle it is not susceptible to damage through ordinary use; however, when it is removed, care must be taken during handling. Such actions as a sharp blow on the end of the steering shaft or shift levers, leaning on the column assembly or dropping of the assembly could loosen or shear the plastic shear joints or rivets used to maintain column rigidity. Hammering, jolting or bumping on the steering shaft and gearshift tube must be avoided during all service operations. If the shear pins are broken, the controlled length of the telescoping design will be altered making these components unfit for further service. When removing the steering wheel, only a steering wheel puller designed for this purpose must be used. It is important that only the specified screws, bolts and nuts be used during the assembly procedure and torqued to specifications to insure proper breakaway action of the column under impact. Avoid using excessively long bolts or fasteners as they may prevent a portion of the steering column from collapsing. When replacing fasteners, replace with ones of the same part number or equivalent. When removing or installing the steering wheel, ignition switch, lock cylinder, turn signal switch, neutral start switch, back-up light switch or adjusting column shift manual transmission linkage refer to the appropriate vehicle chapter. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service Precautions > Page 2705 Steering Column: Description and Operation ENERGY ABSORBING STEERING COLUMNS The energy absorbing function of the steering column allows the column to collapse at a controlled rate during a severe collision. The collapsing action reduces the possibility of the steering wheel being driven rearward towards the driver. If the driver is thrown forward into the steering wheel, the column can collapse even further at the same controlled rate, thereby reducing the force of impact. Several designs of steering column jackets are used. There is the slip-tube design which is held together with plastic inserts or rivets that shear upon impact and allow the column to collapse. And there is the slotted or corrugated mesh design and bellows type design which shorten in length during impact. The shift tube is a two piece design which is held together by injections of plastic that form the interconnecting inserts and shear pins. Under impact, there is a gradual paring away of the inserts by the knife-like edge in the adjoining tube section. The steering shaft is a two piece assembly. The upper piece is solid and has a double flattened lower end. The lower piece is hollow and formed to fit over the double flattened section of the upper piece. The purpose of the double flattened section is to provide continued steering action even though the shaft is completely collapsed. Upon impact, the shear pins break off and the shaft gradually telescopes against resistance provided by the plastic injections. The steering column mounting bracket prevents the column from being shifted towards the driver during impact. It uses two ``breakaway capsules'' that allow the mounting bracket to slip off its attaching points, allowing the steering column to compress or yield in a forward direction under a severe impact from the driver's end. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service and Repair > Removal and Installation Steering Column: Service and Repair Removal and Installation 1980-87 E100-350 SERIES Removal 1. Apply parking brake and disconnect battery ground cable. 2. Remove two flexible coupling to steering shaft flange attaching nuts. 3. Remove shift linkage rod(s) from steering column. 4. Set wheels in straight ahead position and mark relationship of steering wheel and steering column for proper installation. 5. Remove screws from underneath steering wheel, then lift horn switch assembly from steering wheel. 6. Disconnect horn switch wires by pulling spade terminal from blade connectors, then squeeze J-clip ground wire terminal and pull it out of hole in steering wheel. 7. Remove horn switch assembly, then the steering wheel retaining nut. 8. Using suitable puller, remove steering wheel from shaft. When servicing a tilt steering column, the steering wheel must be in the full ``UP'' position when removed. 9. Remove steering column floor opening cover plate screws. 10. On 1980-81 models, remove shroud by pulling shroud tabs out of clip at bottom of column. 11. On 1982-87 models, remove shroud by loosening screw at bottom, placing shift lever in ``1'' on manual 3 speed and automatic transmission models, and spreading shroud and withdrawing it from instrument panel opening while pulling up and away from column. 12. Remove instrument cluster column opening cover. 13. Remove two column bracket to pedal support bracket attaching screws. 14. Disconnect turn signal/hazard warning and ignition switch wiring harnesses. 15. Remove steering column from vehicle, then the support bracket from column. Installation 1. Position steering column in vehicle. 2. Connect turn signal/hazard warning and ignition switch wiring harnesses. 3. Insert steering shaft flange through floor opening so that flange engages flexible coupling, then raise steering column up to pedal support bracket and loosely install column support bolts. When the column has been removed, the flange assembly will be fully telescoped into the column. Gently tap flange down to engage flexible coupling. 4. Loosely install flexible coupling flange nuts and floor plate fasteners. 5. Position steering wheel into place with retaining nut, aligning marks made during removal, and torque nut to 30-40 ft. lbs. 6. Connect spade terminal of horn switch wire to blade connector and press J-clip ground terminal fully into threaded hole. 7. Center horn switch on steering wheel and install attaching screws. 8. On 1980-81 models, align steering column and flexible coupling as follows: a. Pull steering column upward until flexible coupling is positioned between flat, and concaved upward {1/10} inch. b. Torque steering column to support bracket and steering column opening cover plate to dash panel bolts to 8-20 ft. lbs. c. Insert a .010 inch shim between flexible coupling right safety pin and steering column lower flange cutout then turn steering wheel one revolution clockwise. d. If shim cannot be removed, loosen cover plate clamp and plate attaching bolts and realign column until shim can be removed when rotating steering wheel. e. Insert .010 inch shim between flexible coupling left safety pin and lower flange cutout, then turn steering wheel one revolution counterclockwise and check as in step 8d. f. Install trim cover. 9. On 1982-87 models, align steering column and flexible coupling as follows: a. Check for coupling pin to flange cutout clearance of .160 inch, adjusting as necessary. b. Torque flange coupling nuts to 14-21 ft. lbs., steering column to support bracket bolts to 19-27 ft. lbs., steering column floor opening cover plate to dash panel bolts to 12-18 ft. lbs., and steering column opening cover clamp bolt to 12-18 ft. lbs. 10. Attach shift linkage rod(s). 11. Connect battery ground cable. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service and Repair > Removal and Installation > Page 2708 Steering Column: Service and Repair Disassembly Non-Tilt Column Fig. 1 Exploded view of non-tilt steering column. 1980---87 Bronco & F100-350 Series w/3 speed man. trans. Fig. 2 Exploded view of non-tilt steering column. 1980---87 Bronco & F100-350 Series w/4 speed man. trans. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service and Repair > Removal and Installation > Page 2709 Fig. 3 Exploded view of non-tilt steering column. 1980---87 Bronco & F100-350 Series w/auto. trans. 1. Remove turn signal lever. 2. On vehicles equipped with 3 speed manual or automatic transmission, drive out pivot pin and remove hand shift lever. 3. Partially withdraw turn signal/hazard warning switch, and key warning buzzer terminal if equipped, from upper flange, Figs. 1, 2 and 3. 4. Remove snap ring from upper steering shaft. 5. Remove lower bearing retainer from bottom of steering column. 6. Using suitable tool, gently tap steering shaft out of bottom of steering column. Harsh impacts at either end of shaft may alter shaft in overall length, adversely affecting assembly. 7. On 1982 vehicles equipped with automatic transmission, remove shift tube retaining screw from bottom of shift socket. 8. On 1983-87 vehicles equipped with automatic transmission, drill out shift tube retaining rivet from bottom of shift socket. 9. On vehicles equipped with 3 speed manual or automatic transmission, withdraw shift tube assembly from bottom of column. 10. On all vehicles, clip ignition switch in lock position and remove ignition switch and actuator rod. 11. On E100-350 equipped with automatic transmission, remove PRNDL21 hood and lens assembly. 12. On all vehicles, loosen upper flange retaining nuts until only 1 or 2 threads remain engaged, then pinch nuts toward each other and withdraw upper flange from outer tube. 13. On vehicles equipped with 3 speed manual or automatic transmission, remove shift socket from outer tube. 14. On vehicles equipped with 4 speed manual transmission, remove flange extension from outer tube. 15. Remove upper bearing and insulator cover from upper flange by gently tapping from opposite side. 16. Remove flange retaining bolts and nuts. 17. On vehicles with manual transmission, remove snap ring from lock release lever assembly. 18. On vehicles equipped with manual transmission, remove lock release lever assembly through hole on front of flange and remove spring from assembly. 19. On vehicles equipped with automatic transmission, remove PRNDL21 insert from front of flange. 20. On all vehicles, place lock cylinder in ``Run'' position and remove retaining pin, then remove lock cylinder from flange. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service and Repair > Removal and Installation > Page 2710 Fig. 11 Lower Bearing Retainer 21. Remove lock bearing snap ring, then the lock bearing. 22. Remove lock drive gear through lock cylinder opening, then the lock actuator assembly and lock actuator insert. 23. On E100-350, disassemble steering column lower bearing retainer subassembly as follows: a. Remove steering column lower bayonet flange and leaf spring, Fig. 10. Do not loosen leaf spring. b. Remove lower bearing shaft clamp, bolt, and nut. c. Remove 3 screws and the lower bearing assembly. d. Remove split retainer sleeve from lower bearing retainer assembly. 24. On vehicles equipped with 3 speed manual transmission, disassemble shift tube subassembly as follows: a. Hold shift tube above spring and push up and rotate lower shift arm until loading slot in arm aligns with lower key. b. Remove lower arm and lower spacer. c. Rotate upper shift arm until loading slot in arm aligns with lower key,then remove upper arm and upper spacer. d. Remove and discard shift arm grommets. Tilt Column Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service and Repair > Removal and Installation > Page 2711 Fig. 6 Exploded view of tilt steering column (typical). 1980---87 exc. Aerostar, Bronco II & 1983---87 Ranger Fig. 7 Removing wire bale & tilt locking lever Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service and Repair > Removal and Installation > Page 2712 Fig. 8 Removing flange assembly pivot pins 1. Remove steering wheel and steering column, Fig. 6, from vehicle. 2. Remove turn signal actuator lever. 3. On models equipped with automatic transmission, drive out pivot pin and remove shift lever. 4. On 1980-S81 E100-S350 models, remove steering shaft lower flange and retaining clamp. 5. On all models, remove lower bearing retainer. 6. On models equipped with automatic transmission, remove shift tube retaining screw from bottom of shift socket, then slide shift tube out of bottom of column. 7. On all models, remove lock drive gear. 8. Remove turn signal switch attaching screws, then the wiring harness-to-steering column tube clips, if necessary. 9. Remove turn signal switch and harness from steering column. 10. Remove cover casting screws, then the casting from column. 11. Unhook and remove upper actuator from lower actuator. 12. Remove and discard lower flange-to-outer tube attaching screws. 13. Loosen ignition switch nut and washer assemblies and remove ignition rod from switch end. 14. Remove tilt mechanism, steering shaft and ignition actuation rod from steering column upper end. 15. On models equipped with automatic transmission, remove shift socket, then the shift lever indicator ring. 16. On models equipped with manual transmission, remove flange extension, then the key release lever mechanism from tilt mechanism. 17. On all models, remove spring clips holding wire bale, then the bale, Fig. 7. 18. Drive out pin holding locking lever, then remove the lever and spring. 19. Remove column upper shaft snap ring. 20. Remove two pivot pins from side of casting assembly, then separate upper and lower flange castings, Fig. 8. If pivot pins fit loosely in the lower flange, the pins must be discarded. 21. Position flange casting on suitable workbench with smaller bearing facing down. 22. Lightly tap on outer race of small bearing at each slot, using a small drift, and remove race and bearing. 23. Invert flange casting and repeat step 22 on large bearing. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service and Repair > Removal and Installation > Page 2713 Steering Column: Service and Repair Assembly Non-Tilt Column 1. On vehicles equipped with 3 speed manual transmission, place bushing in socket retainer in outer tube. 2. On vehicles equipped with 3 speed manual transmission, place bushing on upper hub and wave washer on lower hub of shift socket. 3. On vehicles equipped with 3 speed manual or automatic transmission, install shift socket in outer tube. 4. On vehicles equipped with 4 speed manual transmission, install flange extension on outer tube. 5. Install lock actuator insert in rear of flange and torque screw to 15---25 inch lbs. 6. Insert lock actuator assembly through opening in front of flange until it bottoms against insert. 7. Install lock drive gear through lock cylinder opening so that last gear tooth aligns with last tooth on actuator assembly when actuator is fully rearward. 8. Install lock bearing, then the lock bearing snap ring. 9. Place lock cylinder in ``ON'' position and depress retaining pin, then insert lock cylinder into flange. 10. On vehicles equipped with automatic transmission, attach PRNDL21 insert to front of flange. 11. On vehicles equipped with manual transmission, position spring on lock release lever assembly and position lever assembly through hole in front of flange, then tighten spring until lever assembly drops into place. 12. On vehicles equipped with manual transmission, install snap ring on lock release lever assembly. 13. On all vehicles, install flange retaining bolts through holes in flange and hand start nuts 1 to 2 threads. 14. On vehicles equipped with automatic transmission, place wave washer in flange hub. 15. Install subassembled flange onto outer tube by pinching nuts toward each other and pressing flange in place, then torque nuts to 60---75 inch lbs. 16. On vehicles equipped with 3 speed manual transmission, assemble shift tube assembly as follows: a. Install grommets in shift tube, small end facing up. b. Stack upper spacer, upper arm, lower spacer, and lower arm concentrically in order so that loading slots align. c. Press entire stack through common loading slot on shift tube, then rotate stack components individually until arms are aligned with their keyways on shift key and spacers allow shift key to pass freely through operating slots. 17. On vehicles with 3 speed manual transmission, load shift tube assembly through lower opening of column. 18. On vehicles equipped with automatic transmission, install shift tube retaining rivet through bottom of shift socket. 19. On all vehicles, install steering shaft clip below knurl for upper bearing. 20. On Bronco and F100-350, ensure that shaft assembly length is 35.6 inches, adjusting as necessary by tapping gently in appropriate direction. 21. Load shaft through bottom of column, being careful not to collapse steering shaft on Bronco and F100-350. 22. Place cover insulator onto upper bearing and press onto knurl of steering shaft until snap ring groove is visible above bearing. 23. Install snap ring on steering shaft in groove above bearing. 24. Install turn signal/hazard warning switch, torquing screws to 15---25 inch lbs. 25. On E100-350, subassemble lower bearing retainer assembly as follows: a. Install split retainer sleeve into lower bearing retainer assembly with sleeve shoulder against bearing. b. Loosely assemble clamp, bolt, and nut to lower bearing retainer assembly, ensuring that bolt aligns with round groove in split retainer sleeve. c. Push split retainer sleeve shoulder down and push clamp toward bearing, and torque clamp nut to 9-18 ft. lbs. 26. On Bronco and F100-350, install lower bearing retainer, ensuring that centerline of coupling shaft attachment hole extends .8 inch below lower face of retainer, and torque screws to 12-20 inch lbs. 27. On E100-350, install lower bearing retainer and telescope steering column lower bayonet shaft fully toward lower end of column. 28. Install ignition switch actuator rod. 29. Install ignition switch and hand start retaining nuts with lock cylinder in lock position. 30. Torque switch retaining nuts to 40-65 inch lbs. and remove clip. 31. Install hand shift lever and secure by driving in pivot pin. 32. Install turn signal switch lever, torquing screws to 30---45 inch lbs. AEROSTAR, BRONCO II & 1983-87 RANGER Tilt Column Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Component Information > Service and Repair > Removal and Installation > Page 2714 Fig. 6 Installing Flange Assembly Pivot Pins 1. Position flange casting on suitable work bench with large bearing seat facing up. 2. Place large upper bearing over seat with open side facing inward. Position a suitable socket on bearing outer race and lightly tap socket until bearing is seated. Use care to avoid contacting bearing inner race as damage will result. 3. Invert flange casting and repeat step 2 on small bearing. 4. Install lower actuator with ignition switch rod attached. 5. Install upper and lower flanges with pivot pins. Ensure column position spring is seated properly between upper and lower flange and wavy thrust washer is properly positioned between lower flange and socket. 6. Install column upper shaft snap ring. 7. Install locking lever, spring and lever pin. 8. Position wire bale on upper casting and install spring clips, Fig. 9. 9. On models equipped with automatic transmission, install shift lever indicator ring on tilt mechanism. Torque attaching screws to 10-20 inch lbs., then install shift socket. 10. On models equipped with manual transmission, attach key release mechanism to tilt mechanism, then install flange extension and torque attaching screws to 10-20 inch lbs. 11. On all models, install tilt mechanism. Feed steering shaft down center of column and ignition actuation rod through shift socket/flange extension along top of column outer tube. 12. Install flange retainer assemblies. Use new screws and torque to 50-68 inch lbs. 13. Install lower bearing retainer, then loosely attach ignition switch to outer tube. 14. Connect upper and lower actuators, then install column cover. Torque cover attaching screws to 40-50 inch lbs. 15. Position turn signal switch and wiring harness in steering column. Attach wiring harness to steering column tube clips, if necessary. 16. Install turn signal switch attaching screws and torque to 20-30 inch lbs. 17. Install turn signal lever, then the lock drive gear. 18. Install lock cylinder with key in ``On'' position. Ensure retaining pin is flush with cylinder. 19. On models equipped with automatic transmission, install shift lever and pivot pin. 20. On all models, install steering column. 1982-87 BRONCO, E100-350 & F100-350 SERIES, NON-TILT STEERING COLUMN Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Sector Shaft > Component Information > Adjustments Sector Shaft: Adjustments GEAR ADJUSTMENTS There are two adjustments on the steering gear: worm bearing preload and pitman shaft overcenter preload. Prior to adjusting the steering gear, all outside loads must be removed. Fig. 3 Steering gear adjustments Fig. 4 Checking adjustment with an inch pound torque wrench WORM BEARING PRELOAD, ADJUST 1. Disconnect battery ground cable, then raise and support vehicle. 2. Remove pitman arm nut, then mark relationship of pitman arm to pitman shaft to aid during reassembly. 3. Remove pitman arm using a suitable puller. 4. Loosen steering gear adjuster plug lock nut, then back off adjuster plug {1/4} turn, Fig. 3. 5. Remove horn pad or button to gain access to the steering wheel attaching nut. 6. Turn steering wheel gently in one direction to stop, then turn back {1/2} turn to position steering gear away from ``high point'' load position. Do not turn wheel hard against steering stops with pitman arm disconnected as damage to the gear ball guides can result. 7. Position suitable inch pound torque wrench on steering wheel hub nut, Fig. 4, then while rotating steering wheel with inch pound wrench through a 90 degree arc, record and measure ``bearing drag.'' Do not use an inch pound wrench of more than 50 inch pound capacity. 8. Adjust worm bearing preload to specifications listed at end of section by turning adjuster plug while measuring turning torque at steering wheel hub with inch pound wrench. Worm bearing preload specification is in excess of ``bearing drag'' determined in previous step. 9. Torque adjuster plug lock nut to 25 ft. lbs., then recheck preload. Rotate steering wheel from stop to stop. If steering gear feels ``lumpy'', bearing damage is indicated. Gear should be disassembled and inspected as necessary. PITMAN SHAFT OVERCENTER PRELOAD, ADJUST 1. Perform steps 1 through 9 of ``Worm Bearing Preload, Adjust'' procedure. 2. Turn steering wheel from one stop to the other while carefully counting the total turns required, then turn wheel back exactly halfway to position steering gear at ``high point.'' 3. Loosen lash adjuster screw lock nut, Fig. 3, then turn adjuster screw clockwise to remove gear lash between ball nut and pinion shaft. Tighten lock nut. 4. Check steering wheel turning torque with suitable inch pound wrench at steering wheel hub, Fig. 4, and compare to specifications listed at end of section. 5. If measurement is not within specifications, loosen lock nut and readjust adjuster screw to obtain proper turning torque. Tighten lock nut and check turning torque through center of steering wheel travel. If maximum turning torque exceeds specifications, turn adjuster screw counterclockwise, then come up on adjustment by turning in a clockwise direction. 6. Assemble pitman arm to pitman shaft. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Component Information > Description and Operation Axle Beam: Description and Operation Fig. 1 Twin I-Beam front axle Fig. 2 Spindle used with twin I Beam front axle. Typical EXC. 4 WHEEL DRIVE MODELS Twin I-Beam Axle As illustrated in Fig. 1 there are two I-beam axles, one for each front wheel. One end of each axle is attached to the spindle and a radius arm and the other end is attached to a frame bracket on the opposite side of the vehicle. Each spindle is held in place on the axle by ball joints or a spindle bolt which pivots in bushings pressed in the upper and lower ends of the spindle, Fig. 2. On models equipped with spindle bolts, a thrust bearing is installed between the lower end of the axle and the spindle to support the load on the axle. On all models, a spindle arm is installed on each spindle for attachment to the steering linkage. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > Suspension - #1 Crossmember Service Replacement Cross-Member: Technical Service Bulletins Suspension - #1 Crossmember Service Replacement Artile No. 83-18-18 FRAME - #1 CROSSMEMBER - SERVICE REPLACEMENT LIGHT TRUCKS 1980-83 F100-350, BRONCO; 1975-83 ECONOLINE Number 1 crossmember kits are now available for usage where damaged crossmembers require complete replacement. The kits will service all vehicles except HD F-250/350 with 6.9L or 7.5L engines. The kits include detailed installation instructions and necessary fasteners to assure a durable replacement. In instances where the crossmember has minimal damage confined to areas surrounding the pivot brackets, complete replacement may not be required. In these cases, your District Zone Service Manager should be contacted regarding the potential usage of a reinforcing kit instead of complete replacement of the crossmember. PART NUMBER PART NAME CLASS D5UZ-5C139-A Kit - #1 Crossmember C Econoline E0TZ-5C139-A Kit - #1 Crossmember C Bronco, F100-350 (Coil Springs) (except 6.9L, 7.5L engines) E0TZ-5C139-B Kit - #1 Crossmember C F-250/350 (4x4) (leaf springs) (except 6.9L, 7.5L engines) OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Service and Repair Front Steering Knuckle: Service and Repair Spindle REMOVE 1. Raise the front of the vehicle and install safety stands. 2. Remove the wheel and tire assembly. 3. Remove the caliper assembly from the rotor and hold it out of the way with wire. 4. Remove the dust cap, cotter pin, nut retainer, nut, washer, and outer bearing, and remove the rotor from the spindle. 5. Remove inner bearing cone and seal. Discard the seal. 6. Remove brake dust shield. 7. Disconnect the steering linkage from the spindle arm by removing the cotter pin and nut, and then removing the tie rod end from the spindle arm with tie Rod End Remover, TOOL-3290-D or equivalent. 8. Remove the nut and lockwasher from the lock pin, and remove the lock pin. 9. Remove the upper and lower spindle pin plugs; then, drive the spindle pin out from the top of the axle and remove the spindle and thrust bearing. Remove the spindle pin seal and thrust bearing. INSTALL 1. Make sure the spindle pin hole in the axle is free of nicks, burrs, corrosion or foreign material. Clean up the bore as necessary and lightly coat the surface with a lithium-base grease, Long-Life Lubricant, C1AZ-19590-BA (ESA-M1C75-B) or equivalent. 2. Install a new spindle pin seal with the metal backing facing up towards the bushing into the spindle. Gently press seal into position, being careful not to distort the casing. 3. Install a new thrust bearing with the lip flange facing down towards the lower bushing. Press until the bearing is firmly seated against the surface of the spindle. 4. Lightly coat the bushing surfaces with grease and place the spindle in position on the axle. 5. Hold the spindle with thrust bearing in place tight against the axle and measure the space between the axle and the spindle at the top of the axle. If the vehicle uses shims, select the proper shims and install. 6. Install the spindle pin with the "T" stamped on one end towards the top, and the notch in the pin aligned with the lock pin hole in the axle. Insert the spindle pin through the bushings and axle from the top until the spindle pin notch and axle lock pin hole are in line. 7. Install the lock pin with the threads pointing forward and the wedge groove facing the spindle pin notch. Firmly drive the lock pin into position and mount the lockwasher and nut. Tighten the nut to 52-84 Nm (38-62 ft lb). 8. Install the spindle pin plugs into the threads at the top and bottom of the spindle. Tighten the plugs to 48-67 Nm (35-50 ft lb). 9. Lubricate the spindle pin and bushings with Long-Life Lubricant C1AZ-19590-BA (ESA-M1C75-B) or equivalent, through both fittings until grease is visible seeping past the upper seal at the top and from the thrust bearing slip joint at the bottom. If grease does not appear, recheck the installation procedure to correct the problem. Lack of adequate lubrication will result in rapid failure of the spindle components. 10. Install the dust shield. 11. Pack the inner and outer bearing cone with bearing grease. Use a bearing packer. If a bearing packer is unavailable, pack the bearing cone by hand working the grease through the cage behind the rollers. 12. Install the inner bearing cone and seal. Install the hub and rotor on the spindle. 13. Install the outer bearing cone, washer, and nut. Adjust bearing end play and install the nut retainer, cotter pin and dust cap. 14. Install the caliper. 15. Connect the steering tie rod and drag link (if equipped) to the spindle. Tighten the nut to specifications and advance the nut as required for installation of the cotter pin. 16. Install the wheel and tire assembly. 17. Lower the vehicle. 18. Check and, if necessary adjust the toe setting. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle Pin <--> [King Pin] > Component Information > Technical Service Bulletins > King Pin - Service Procedure Spindle Pin: Technical Service Bulletins King Pin - Service Procedure Article No. 83-4-13 KING PIN SERVICE SPINDLE THREAD PROTECTION - VEHICLES WITH FORGED AXLES LIGHT TRUCKS 1975-83 ECONOLINE & F100-350 TSB 82-11-8 dated June 4, 1982 described the recommended king pin service procedure and referenced the use of a hydraulic press to remove the spindle pin. For dealerships that do not have such a press and normally remove the spindle pin by using a drift pin, the following procedure is suggested to prevent spindle damage. 1. Remove upper/lower grease plug from the spindle being serviced (both spindles if required). 2. Remove the zerk fitting from one of the grease plugs. Clean grease plug. 3. Using the zerk fitting hole as a piloting hole, drill out the grease plug to any desired diameter up to a maximum of 3/4". 4. After drilling is complete, re-install the modified grease plug in upper spindle. 5. Remove spindle pin by inserting a drift pin through the hole in the grease plug and striking with a mallet. The grease plug will provide protection for the threads in the spindle. 6. After service is completed, remove modified grease cap. If necessary to replace spindle bushings, use king pin bushing tool T53T-3110-A to remove old bushings and install new bushings. Reassemble with new service components as required. 7. If service is required on other spindle, install modified grease cap to protect spindle threads. 8. Save modified grease cap for use on other similar vehicles. OTHER APPLICABLE ARTICLES: 82-11-8 WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle Pin <--> [King Pin] > Component Information > Technical Service Bulletins > Page 2734 Spindle Pin: Service and Repair Spindle Bushings Spindle Bushing Tools REMOVE 1. Remove the spindle. Refer to Spindle/Service and Repair. 2. The bronze spindle bushings have an inside diameter of 0.8600/0.8610 inch, use the following tools: Reamer T53T-31 10-DA Bushing Remover/Installer Driver D82T-3110-0 and Driver Handle D82T-3110-C or equivalents. NOTE: Each side of the Bushing Remover/Installer Driver tool is marked with a "T" or a "B". Use the side with the "T" stamping to install the top spindle bushing. Use the side with the "B" stamping to install the bottom spindle bushing. 3. Remove and discard the seal from the bottom of the upper bushing bore of the upper spindle yoke. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle Pin <--> [King Pin] > Component Information > Technical Service Bulletins > Page 2735 Spindle Bushing Service 4. Remove and install the top spindle bushing first. Install the driver handle through the bottom bore. Position a new bushing on the "T" side stamping of the bushing Remover/Installer Driver. The bushing must be installed on the tool so the open end grooves will face outward when installed. Position the new bushing and driver over the old bushing, insert the handle into the driver and drive the old bushing out while the new bushing is driven in. Drive until the tool is seated. The bushing will then be seated at the proper depth (2.03 mm [0.080 inch)] minimum from bottom of upper spindle boss). Spindle Bushing Service 5. Remove and install the bottom spindle bushing. Install the Driver Handle through the top bushing bore. Position a new bushing on the "B" side stamping of the Bushing Remover/Installer Driver. The bushing must be installed on the tool so the open-end grooves will face outward when installed. Position the new bushing and driver over the old bushing in the bottom spindle bore. Insert the handle into the driver and drive the old bushing out while the new bushing is driven in. Drive until the tool is seated. The bottom bushing will then be seated at the proper depth (3.30 mm [0.130 inch] minimum from the top of the lower spindle boss). Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle Pin <--> [King Pin] > Component Information > Technical Service Bulletins > Page 2736 Spindle Bushing Service 6. Ream the new bushings to 0.025-0.076 mm (0.001-0.003 inch) larger than the diameter of a new spindle pin. Ream the top bushing first with the reamer tool. Install the smaller diameter of the tool through the top bore and into the bottom bore until the reaming threads are in position in the top bushing. Turn the tool until the threads exit the top bushing. Ream the bottom bushing. The larger diameter portion of the tool will act as a pilot in the top bushing to properly ream the bottom bushing. 7. Clean all the metal shavings from the bronze bushings after reaming. Coat the bushings and spindle pin with Long Life Lubricant, C1AZ-19590-BA (ESA-M1C75-B) or equivalent. 8. Install a new seal on Bushing Remover/Installer Driver tool on the side with the "T" stamping. Install the handle into the driver and push the seal into position in the bottom of the top bushing bore. INSTALL 1. Reverse removal procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Suspension > Radius Arm > Component Information > Service and Repair Radius Arm: Service and Repair EXC. 4 WHEEL DRIVE MODELS 1. Remove coil spring as described under ``Coil Spring, Replace''. 2. Remove spring lower seat from radius arm. 3. Remove radius arm and stabilizer bracket (if equipped) attaching nut and bolt from axle. 4. On all except 1983---87 E-100---350 models, remove nut, rear washer, insulator and spacer from rear side of radius arm rear bracket. 5. On 1980 models, disconnect tie rod end. 6. On all models, remove radius arm from vehicle. 7. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Technical Service Bulletins > Axle - Axle to Spindle Thrust Bearing Clearance Spindle: Technical Service Bulletins Axle - Axle to Spindle Thrust Bearing Clearance Article No. 84-22-6 AXLE - FRONT - AXLE TO SPINDLE THRUST BEARING CLEARANCE/FREEPLAY LIGHT TRUCKS 1975 & LATER ECONOLINE King pin thrust bearing shims are not utilized on Econoline axle and after market king pin kit shims should not be used. The gap between the axle and spindle interface should be measured with a feeler gauge or freeplay measured with a dial indicator. Clearance of .050" or less is acceptable. Clearances in excess of .050" indicate that the thrust bearing is worn down and should be replaced. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Technical Service Bulletins > Page 2744 Spindle: Service and Repair Spindle REMOVE 1. Raise the front of the vehicle and install safety stands. 2. Remove the wheel and tire assembly. 3. Remove the caliper assembly from the rotor and hold it out of the way with wire. 4. Remove the dust cap, cotter pin, nut retainer, nut, washer, and outer bearing, and remove the rotor from the spindle. 5. Remove inner bearing cone and seal. Discard the seal. 6. Remove brake dust shield. 7. Disconnect the steering linkage from the spindle arm by removing the cotter pin and nut, and then removing the tie rod end from the spindle arm with tie Rod End Remover, TOOL-3290-D or equivalent. 8. Remove the nut and lockwasher from the lock pin, and remove the lock pin. 9. Remove the upper and lower spindle pin plugs; then, drive the spindle pin out from the top of the axle and remove the spindle and thrust bearing. Remove the spindle pin seal and thrust bearing. INSTALL 1. Make sure the spindle pin hole in the axle is free of nicks, burrs, corrosion or foreign material. Clean up the bore as necessary and lightly coat the surface with a lithium-base grease, Long-Life Lubricant, C1AZ-19590-BA (ESA-M1C75-B) or equivalent. 2. Install a new spindle pin seal with the metal backing facing up towards the bushing into the spindle. Gently press seal into position, being careful not to distort the casing. 3. Install a new thrust bearing with the lip flange facing down towards the lower bushing. Press until the bearing is firmly seated against the surface of the spindle. 4. Lightly coat the bushing surfaces with grease and place the spindle in position on the axle. 5. Hold the spindle with thrust bearing in place tight against the axle and measure the space between the axle and the spindle at the top of the axle. If the vehicle uses shims, select the proper shims and install. 6. Install the spindle pin with the "T" stamped on one end towards the top, and the notch in the pin aligned with the lock pin hole in the axle. Insert the spindle pin through the bushings and axle from the top until the spindle pin notch and axle lock pin hole are in line. 7. Install the lock pin with the threads pointing forward and the wedge groove facing the spindle pin notch. Firmly drive the lock pin into position and mount the lockwasher and nut. Tighten the nut to 52-84 Nm (38-62 ft lb). 8. Install the spindle pin plugs into the threads at the top and bottom of the spindle. Tighten the plugs to 48-67 Nm (35-50 ft lb). 9. Lubricate the spindle pin and bushings with Long-Life Lubricant C1AZ-19590-BA (ESA-M1C75-B) or equivalent, through both fittings until grease is visible seeping past the upper seal at the top and from the thrust bearing slip joint at the bottom. If grease does not appear, recheck the installation procedure to correct the problem. Lack of adequate lubrication will result in rapid failure of the spindle components. 10. Install the dust shield. 11. Pack the inner and outer bearing cone with bearing grease. Use a bearing packer. If a bearing packer is unavailable, pack the bearing cone by hand working the grease through the cage behind the rollers. 12. Install the inner bearing cone and seal. Install the hub and rotor on the spindle. 13. Install the outer bearing cone, washer, and nut. Adjust bearing end play and install the nut retainer, cotter pin and dust cap. 14. Install the caliper. 15. Connect the steering tie rod and drag link (if equipped) to the spindle. Tighten the nut to specifications and advance the nut as required for installation of the cotter pin. 16. Install the wheel and tire assembly. 17. Lower the vehicle. 18. Check and, if necessary adjust the toe setting. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Component Information > Service and Repair Stabilizer Bar: Service and Repair 1. Disconnect both ends of stabilizer bar from link assembly on I-beam bracket. 2. On 1986---87 F-350 models equipped with Dana 60 Monobeam axle, remove nuts, washers and bolts securing links to mounting brackets. 3. Remove stabilizer bar attaching bolts and the stabilizer bar. On 1980---87 F-150 4 4 and Bronco models, the coil spring must be removed to facilitate removal of the stabilizer bar mounting bracket. 4. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Suspension > Subframe > Component Information > Technical Service Bulletins > Suspension - #1 Crossmember Service Replacement Subframe: Technical Service Bulletins Suspension - #1 Crossmember Service Replacement Artile No. 83-18-18 FRAME - #1 CROSSMEMBER - SERVICE REPLACEMENT LIGHT TRUCKS 1980-83 F100-350, BRONCO; 1975-83 ECONOLINE Number 1 crossmember kits are now available for usage where damaged crossmembers require complete replacement. The kits will service all vehicles except HD F-250/350 with 6.9L or 7.5L engines. The kits include detailed installation instructions and necessary fasteners to assure a durable replacement. In instances where the crossmember has minimal damage confined to areas surrounding the pivot brackets, complete replacement may not be required. In these cases, your District Zone Service Manager should be contacted regarding the potential usage of a reinforcing kit instead of complete replacement of the crossmember. PART NUMBER PART NAME CLASS D5UZ-5C139-A Kit - #1 Crossmember C Econoline E0TZ-5C139-A Kit - #1 Crossmember C Bronco, F100-350 (Coil Springs) (except 6.9L, 7.5L engines) E0TZ-5C139-B Kit - #1 Crossmember C F-250/350 (4x4) (leaf springs) (except 6.9L, 7.5L engines) OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Rear Suspension Spring ( Coil / Leaf ): Service and Repair Rear E-100---350 1. Raise rear of vehicle and support at frame. Support axle with a suitable jack. 2. Disconnect shock absorbers from lower mountings. 3. Remove 2 U-bolts and the U-bolt plate. 4. On E-100---150 models, lower axle assembly and remove upper and lower rear shackle bolts, then pull rear shackle assembly from bracket and spring. Remove spring mounting nut and bolt, then lower spring assembly from vehicle. 5. On E-250---350 models, lower axle assembly and remove spring front bolt from hanger. Remove 2 attaching bolts from rear of spring, then lower spring assembly from vehicle. 6. On all models, reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Rear > Page 2756 Suspension Spring ( Coil / Leaf ): Service and Repair Coil Spring EXC. 4 WHEEL DRIVE MODELS 1. Raise front of vehicle and support with stands. Support axle with a suitable jack. The axle must be supported when replacing spring and not be permitted to hang by brake hose. If length of brake hose is not sufficient to permit spring replacement, it will be necessary to remove the disc brake caliper. Do not suspend caliper by brake hose, if removed. 2. Disconnect shock absorber from lower mounting. 3. Remove spring upper retainer attaching bolts and the retainer. 4. Remove spring lower retainer attaching nut and the retainer. 5. Lower axle slowly and remove spring from vehicle. 6. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Air Shock Absorber Suspension Strut / Shock Absorber: Service and Repair Front Air Shock Absorber 1. Disconnect shock absorber from upper mounting. 2. Disconnect shock absorber from lower mounting, then compress shock and remove from vehicle. 3. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Air Shock Absorber > Page 2761 Suspension Strut / Shock Absorber: Service and Repair Rear 1. Raise and support rear of vehicle to a point where weight is relieved from rear springs and tires are still in contact with floor. 2. Remove lower attaching nut and bolt from shock absorber and swing lower end free of mounting bracket. 3. Remove upper attaching nut and the shock absorber. 4. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Adjustments Wheel Bearing: Adjustments EXCEPT 4 WHEEL DRIVE MODELS 1. Remove wheel and tire assembly, disc brake caliper and pads, dust cap, locknut, adjusting nut, washer and cotter pin. 2. Tighten wheel adjusting nut to 22-25 ft. lbs. while rotating disc brake rotor in opposite direction. 3. Back off wheel retention nut 1/8 turn and install retainer and cotter pin without any additional movement of nut. 4. Reinstall dust cap, caliper, pads and tire and wheel assembly. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Adjustments > Page 2765 Wheel Bearing: Service and Repair EXC. 4 WHEEL DRIVE MODELS 1. Raise and support front of vehicle and remove front wheels. 2. Remove brake caliper and position aside, leaving brake lines attached. Do not allow weight of caliper to hang on brake lines. 3. Remove grease cap, cotter pin, locknut, adjusting nut and washer, then the outer bearing cone and roller. 4. Remove hub and rotor and discard grease retainer. 5. Remove inner bearing and roller. 6. Reverse procedure to install. Adjust bearings as described under ``Wheel Bearings, Adjust''. 4 WHEEL DRIVE MODELS 1. Raise and support front of vehicle and remove front wheels. 2. On models equipped with locking hubs, remove hubs as described in ``Front Wheel Drive Section''. 3. On 1980---81 models, remove front hub grease cap. 4. On 1980---81 models, remove driving hub snap ring, then the splined driving hub and pressure spring. 5. On all models, remove wheel bearing locknut, lock ring and adjusting nut, then the hub and disc assembly. The outer bearing and roller assembly will slide out when the hub is removed. 6. Remove inner bearing and grease seal from wheel hub using a suitable driving tool on 1980---81 models or a puller on 1982---87 models. 7. Reverse procedure to install. Adjust bearings as described under ``Wheel Bearings, Adjust''. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 851916 > Sep > 85 > Tires - Front Outside Edge Wear Tires: Customer Interest Tires - Front Outside Edge Wear Article No. 85-19-16 TIRE WEAR - FRONT - OUTSIDE EDGE LIGHT TRUCK 1976-86 E100-150 Outboard shoulder wear, predominantly in lightly loaded city-delivery type use, is aggravated by excessive positive wheel camber in turning. The caster adjustment kit described in TSB 85-19-15 can be used to increase caster of either wheel up to 3 degrees in 1/2 degree increments. The kit contains complete instructions for modifying the front radius arms and mounting a metal adjusting cam to the bottom flange of each radius arm. Cams must be arc-welded a minimum of one inch along two sides of the cam to the lower flange of the radius arm. Increasing caster the full 3 degrees effectively reduces camber of the outboard wheel in a turn 1.5 degrees. Increasing caster more than 3 degrees is not recommended since this may cause complaints of wheel shimmy and/or excessive steering efforts. Also, caster should not be increased on vehicles built since April 1, 1984. These vehicles have the 3 degree caster increase already built into the axles which have axle part numbers E4UA-6-BA and E4UA-7-BA embossed on the face of each axle. Three other significant factors may also contribute to outboard shoulder wear. They are excessive toe-in (generally greater than 5/32 inch), excessive cornering speeds, and low tire pressure. After any adjustments to front end alignment, toe should be adjusted to zero. On vehicles subject to extensive city-delivery use, toe may be set up to 1/16 inch toe-out for optimum tire life. PART NUMBER PART NAME CLASS E5TZ-3K064-A Kit Caster Adjustment C OTHER APPLICABLE ARTICLES: 85-19-15 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3360B85T TIME: 4.6 Hrs. OPERATION: 3001A TIME: 0.5 Hr. - Check caster camber and toe-in DLR. CODING: Basic Part No. 3A360 - Code: 36 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 851916 > Sep > 85 > Tires - Front Outside Edge Wear Tires: All Technical Service Bulletins Tires - Front Outside Edge Wear Article No. 85-19-16 TIRE WEAR - FRONT - OUTSIDE EDGE LIGHT TRUCK 1976-86 E100-150 Outboard shoulder wear, predominantly in lightly loaded city-delivery type use, is aggravated by excessive positive wheel camber in turning. The caster adjustment kit described in TSB 85-19-15 can be used to increase caster of either wheel up to 3 degrees in 1/2 degree increments. The kit contains complete instructions for modifying the front radius arms and mounting a metal adjusting cam to the bottom flange of each radius arm. Cams must be arc-welded a minimum of one inch along two sides of the cam to the lower flange of the radius arm. Increasing caster the full 3 degrees effectively reduces camber of the outboard wheel in a turn 1.5 degrees. Increasing caster more than 3 degrees is not recommended since this may cause complaints of wheel shimmy and/or excessive steering efforts. Also, caster should not be increased on vehicles built since April 1, 1984. These vehicles have the 3 degree caster increase already built into the axles which have axle part numbers E4UA-6-BA and E4UA-7-BA embossed on the face of each axle. Three other significant factors may also contribute to outboard shoulder wear. They are excessive toe-in (generally greater than 5/32 inch), excessive cornering speeds, and low tire pressure. After any adjustments to front end alignment, toe should be adjusted to zero. On vehicles subject to extensive city-delivery use, toe may be set up to 1/16 inch toe-out for optimum tire life. PART NUMBER PART NAME CLASS E5TZ-3K064-A Kit Caster Adjustment C OTHER APPLICABLE ARTICLES: 85-19-15 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP3360B85T TIME: 4.6 Hrs. OPERATION: 3001A TIME: 0.5 Hr. - Check caster camber and toe-in DLR. CODING: Basic Part No. 3A360 - Code: 36 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 841919 > Sep > 84 > Steering - Pull/Drift Diagnostic Procedures Tires: All Technical Service Bulletins Steering - Pull/Drift Diagnostic Procedures Article No. 84-19-19 STEERING PULL/DRIFT/ROADABILITY - DIAGNOSTIC PROCEDURES LIGHT TRUCKS 1980-84 F100-350, BRONCO, ECONOLINE Section 19 of the 1983 and 1984 Light Truck Shop Manuals provides procedures to resolve most roadability concerns experienced to date. These procedures can be applied to any 1980 and later model light trucks. When servicing 4 wheel drive vehicles with limited slip front axles, front tire circumference is the most probable cause if the pull is only present when the hubs are locked. Installing the two most evenly matched tires on the front axle should resolve the concern. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 841919 > Sep > 84 > Steering - Pull/Drift Diagnostic Procedures Tires: All Technical Service Bulletins Steering - Pull/Drift Diagnostic Procedures Article No. 84-19-19 STEERING PULL/DRIFT/ROADABILITY - DIAGNOSTIC PROCEDURES LIGHT TRUCKS 1980-84 F100-350, BRONCO, ECONOLINE Section 19 of the 1983 and 1984 Light Truck Shop Manuals provides procedures to resolve most roadability concerns experienced to date. These procedures can be applied to any 1980 and later model light trucks. When servicing 4 wheel drive vehicles with limited slip front axles, front tire circumference is the most probable cause if the pull is only present when the hubs are locked. Installing the two most evenly matched tires on the front axle should resolve the concern. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Adjustments Wheel Bearing: Adjustments EXCEPT 4 WHEEL DRIVE MODELS 1. Remove wheel and tire assembly, disc brake caliper and pads, dust cap, locknut, adjusting nut, washer and cotter pin. 2. Tighten wheel adjusting nut to 22-25 ft. lbs. while rotating disc brake rotor in opposite direction. 3. Back off wheel retention nut 1/8 turn and install retainer and cotter pin without any additional movement of nut. 4. Reinstall dust cap, caliper, pads and tire and wheel assembly. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Adjustments > Page 2792 Wheel Bearing: Service and Repair EXC. 4 WHEEL DRIVE MODELS 1. Raise and support front of vehicle and remove front wheels. 2. Remove brake caliper and position aside, leaving brake lines attached. Do not allow weight of caliper to hang on brake lines. 3. Remove grease cap, cotter pin, locknut, adjusting nut and washer, then the outer bearing cone and roller. 4. Remove hub and rotor and discard grease retainer. 5. Remove inner bearing and roller. 6. Reverse procedure to install. Adjust bearings as described under ``Wheel Bearings, Adjust''. 4 WHEEL DRIVE MODELS 1. Raise and support front of vehicle and remove front wheels. 2. On models equipped with locking hubs, remove hubs as described in ``Front Wheel Drive Section''. 3. On 1980---81 models, remove front hub grease cap. 4. On 1980---81 models, remove driving hub snap ring, then the splined driving hub and pressure spring. 5. On all models, remove wheel bearing locknut, lock ring and adjusting nut, then the hub and disc assembly. The outer bearing and roller assembly will slide out when the hub is removed. 6. Remove inner bearing and grease seal from wheel hub using a suitable driving tool on 1980---81 models or a puller on 1982---87 models. 7. Reverse procedure to install. Adjust bearings as described under ``Wheel Bearings, Adjust''. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Lug Nuts - Proper Installation/Torqueing Procedure Wheel Fastener: Technical Service Bulletins Lug Nuts - Proper Installation/Torqueing Procedure Article No. 98-5A-4 ^ BRAKES - PREVENTING BRAKE VIBRATION - SERVICE TIP ^ WHEELS - PROPER LUG TORQUE PROCEDURES - SERVICE TIP FORD: 1972-97 THUNDERBIRD 1976-86 LTD 1976-97 MUSTANG 1981-97 CROWN VICTORIA 1982-88 EXP 1982-98 ESCORT 1984-94 TEMPO 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1979-83 MONARCH, ZEPHYR 1979-97 COUGAR 1980-83 MARK VI 1980-98 CONTINENTAL, TOWN CAR 1981-86 LYNX 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-97 SABLE 1987-89 TRACER 1987-97 GRAND MARQUIS 1991-94 CAPRI 1991-97 TRACER 1993-98 MARK VIII 1995-98 MYSTIQUE LIGHT TRUCK: 1979-96 BRONCO 1979-97 ECONOLINE, F-150-350 SERIES 1984-90 BRONCO II 1984-97 RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-98 WINDSTAR 1997 EXPEDITION 1998 NAVIGATOR ISSUE: The use of air impact tools to tighten wheel lug nuts can lead to overtightened and/or unevenly tightened wheel lug nuts. Air impact tools typically used for wheel lug nut removal and installation can generate up to 475 N.m (350 lb-ft) of torque. Overtightened and/or unevenly torqued wheel lug nuts may cause: ^ Brake vibration ^ Distortion of the wheel hub ^ Distortion of the brake rotor Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Lug Nuts - Proper Installation/Torqueing Procedure > Page 2797 ^ Brake rotor runout ^ Damage to the wheel ^ Damage to the wheel nuts and studs ACTION: All wheel lug nuts should only be tightened to specification using a torque wrench or by using the Rotunda ACCUTORO 164-R0314 or equivalent on a 1/2" drive air impact tool. The "ACCUTORO" lug nut sockets limit the torque of the air impact tool, preventing overtightening or uneven tightening of the wheel lug nuts. The torque limiting devices (regulators) on air impact tools will not reduce the output torque enough to prevent overtightening of the wheel lug nuts. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Lug Nuts - Proper Installation/Torqueing Procedure > Page 2798 NOTE: REFER TO THE APPROPRIATE SERVICE MANUAL OR THE CHART IN FIGURE 1 FOR THE CORRECT WHEEL LUG NUT TORQUE SPECIFICATION. THE CHART IN FIGURE 1 ALSO PROVIDES THE CORRECT "ACCUTORO" LUG NUT SOCKET TO USE. The "ACCUTORO" socket is intended for lug nut installation, not removal. When using the "ACCUTORO" socket, the output torque of the air impact tool must be set to 217-339 N.m (160-250 lb-ft), usually this will be the lowest setting on the air impact tool. The "ACCUTORO" lug nut sockets are available through Rotunda Equipment. The four-piece set (164-R0314) fits most Ford Motor Company cars and light trucks. The tool set consists of four (4) lug nut sockets and a storage case. The set can be ordered by calling Rotunda Equipment at 1-800-ROT-UNDA (768-8632). CAUTION: AIR IMPACT TOOLS SHOULD NOT BE USED TO TIGHTEN WHEEL LUG NUTS UNLESS THE "ACCUTORO" LUG NUT SOCKET OF THE CORRECT SPECIFICATION IS USED. NOTE: DO NOT USE AIR IMPACT TOOLS ON LOCKING WHEEL LUG NUTS. THEY ARE TO BE HAND-TORQUED ONLY. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-17-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 303000, 306000 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Air Door Actuator Air Door Actuator / Motor: Locations Air Door Actuator Rear Middle Of Plenum Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations > Air Door Actuator > Page 2805 Air Door Actuator / Motor: Locations Blend Door Motor Heat/Defrost Vacuum Motor Inside Middle Part Of Plenum Outside-Recirculate Door Vacuum Motor Rear Of Engine Compartment Above RH Rear Side Of Engine Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Aspirator, HVAC > Component Information > Technical Service Bulletins > A/C Aspirator Drain Tube Kit - Service Only Aspirator: Technical Service Bulletins A/C Aspirator Drain Tube Kit - Service Only Article No. 84-18-21-S A/C ASPIRATOR DRAIN TUBE KIT - SERVICE ONLY - ECONOLINE VEHICLES BUILT FROM 1975 THROUGH FEBRUARY, 1984 LIGHT TRUCKS 1975-84 ECONOLINE Part number E4UYZ-19858-D shown in Article No. 84-18-21 is incorrect. The correct part umber is E4UZ- 19858-B. Please cross reference this to TSB No. 84-18, page 33. PART NUMBER PART NAME CLASS E4UZ-19858-B A/C Aspirator Drain Tube Kit B OTHER APPLICABLE ARTICLES: Article No. 84-18-21 WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor: > 851019 > May > 85 > A/C Blower Motor - Inoperative Blower Motor: Customer Interest A/C Blower Motor - Inoperative Article No. 85-10-19 AIR CONDITIONING - INOPERATIVE BLOWER MOTOR - DAMAGED FUSE OR FUSE HOLDER LIGHT TRUCK ALL 1985 AND PRIOR ECONOLINES When operating the A/C system for long periods of time with the blower motor set on high, the solder at the end of the A/C fuse melts with the additional loss of holder clip retention due to the heat build-up. A revised fuse holder is released to resolve the subject concern. The following procedure should be performed: 1. Check fuse for damage (solder melted at end of fuse). 2. Check fuse holder for proper retention of fuse (loss of fuse holder clip retention due to heat build-up). 3. If the fuse or fuse holder show no heat damage perform normal diagnostic procedures for inoperative A/C blower motor. If the fuse or fuse holder is found to be damaged as described in Steps 1 and 2 continue with Step 4. 4. Disconnect battery ground cable. 5. Remove two fuse panel retaining screws and turn fuse panel to expose back side of panel. 6. Locate the two orange wires (Circuit 181) leading to the A/C fuse holder. Cut both wires as close to the fuse panel as possible and remove the fuse holders from the fuse panel. 7. Install in-line fuse holder E5FZ-14517-A using 30 amp fuse D9ZZ-14526-G (green). Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor: > 851019 > May > 85 > A/C Blower Motor - Inoperative > Page 2818 Figure 23FUSE PANEL MOUNTED TO DASH PANEL LEFT OF STEERING COLUMN 8. Tape the fuse holder along the main wire harness as shown in Figure 23. 9. Re-install fuse panel, connect battery ground cable and check A/C system for proper operation. PART NUMBER PART NAME CLASS E5FZ-14517-A Fuse Holder R D9ZZ-14526-G Fuse A OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP14411A85 TIME: 0.4 Hr. DLR. CODING: Basic Part No. 14401 - Code: 28 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor: > 851019 > May > 85 > A/C Blower Motor - Inoperative Blower Motor: All Technical Service Bulletins A/C Blower Motor - Inoperative Article No. 85-10-19 AIR CONDITIONING - INOPERATIVE BLOWER MOTOR - DAMAGED FUSE OR FUSE HOLDER LIGHT TRUCK ALL 1985 AND PRIOR ECONOLINES When operating the A/C system for long periods of time with the blower motor set on high, the solder at the end of the A/C fuse melts with the additional loss of holder clip retention due to the heat build-up. A revised fuse holder is released to resolve the subject concern. The following procedure should be performed: 1. Check fuse for damage (solder melted at end of fuse). 2. Check fuse holder for proper retention of fuse (loss of fuse holder clip retention due to heat build-up). 3. If the fuse or fuse holder show no heat damage perform normal diagnostic procedures for inoperative A/C blower motor. If the fuse or fuse holder is found to be damaged as described in Steps 1 and 2 continue with Step 4. 4. Disconnect battery ground cable. 5. Remove two fuse panel retaining screws and turn fuse panel to expose back side of panel. 6. Locate the two orange wires (Circuit 181) leading to the A/C fuse holder. Cut both wires as close to the fuse panel as possible and remove the fuse holders from the fuse panel. 7. Install in-line fuse holder E5FZ-14517-A using 30 amp fuse D9ZZ-14526-G (green). Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor: > 851019 > May > 85 > A/C Blower Motor - Inoperative > Page 2824 Figure 23FUSE PANEL MOUNTED TO DASH PANEL LEFT OF STEERING COLUMN 8. Tape the fuse holder along the main wire harness as shown in Figure 23. 9. Re-install fuse panel, connect battery ground cable and check A/C system for proper operation. PART NUMBER PART NAME CLASS E5FZ-14517-A Fuse Holder R D9ZZ-14526-G Fuse A OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP14411A85 TIME: 0.4 Hr. DLR. CODING: Basic Part No. 14401 - Code: 28 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Page 2825 Blower Motor: Locations Attached To RH Side Of Dash Panel Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Page 2826 Blower Motor: Service and Repair Fig. 15 Blower motor replacement. E-100---350 less air conditioning E-100---350 Less Air Conditioning 1. Disconnect battery ground cable. 2. Disconnect blower motor electrical connector, then remove ground wire screw from dash. 3. Disconnect cooling tube from blower motor, if equipped. 4. Remove 4 blower motor attaching screws and the blower motor, Fig. 15. 5. Reverse procedure to install. Fig. 16 Blower motor replacement. E-100---350 w/air conditioning W/Air Conditioning 1. Disconnect battery ground cable. 2. Disconnect electrical connectors from resistor on front of blower scroll cover. 3. Remove blower scroll cover attaching screws and the scroll cover, Fig. 16. 4. Push wiring grommet out through hole in blower motor housing. 5. Remove 4 blower motor attaching screws and the blower motor. 6. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations Blower Motor Resistor: Locations Part Of Blower Motor Assembly Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations > Auxiliary Blower Switch Blower Motor Switch: Locations Auxiliary Blower Switch RH Side Of Function Control Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations > Auxiliary Blower Switch > Page 2834 Blower Motor Switch: Locations Front Blower Switch LH Side Of Control Assembly Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Technical Service Bulletins > A/C - Warner Compressor Clutch Replacement Compressor Clutch: Technical Service Bulletins A/C - Warner Compressor Clutch Replacement Article No. 85-4-3 AIR CONDITIONING - REPLACEMENT OF WARNER A/C COMPRESSOR CLUTCH ASSEMBLY FORD 1980-84 ALL LINCOLN-MERCURY 1980-84 ALL LIGHT TRUCK 1980-84 ALL LIGHT TRUCKS When existing stock of 1980-84 Warner Electric A/C compressor clutch hub and pulley parts is exhausted, it will be necessary to replace the entire clutch assembly, including the field coil, with current Ford manufactured clutch parts. Replacement of the Warner field coil is necessary because it is not compatible with the Ford clutch parts. The Warner field coil will continue to be available for replacement on Warner clutch assemblies. NOTE: Never intermix clutch parts from different manufacturers. Refer to the Master Parts Catalog for part numbers and vehicle application. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment Evaporator Case: Customer Interest A/C - Condensate Leaks Into Passenger Compartment Article No. 86-23-14 A/C CONDENSATE LEAKS INTO PASSENGER COMPARTMENT OR DISCHARGES FROM THE INSTRUMENT PANEL REGISTERS LIGHT TRUCK 1975-87 ECONOLINE Condensate may leak from the blower motor area or be expelled through the A/C registers during high temperature/high humidity conditions when the system is operated in Norm A/C and high blower. In these cases, condensate collects in the temperature blend door area and leaks out the seams of the blower case and/or becomes airborne and is expelled through the A/C registers. Check to assure that the evaporator housing has been sealed and the straight condensate drain tube has been installed as outlined in this article. Then, procure and install a new venturi tube and deflector in the evaporator assembly using the following service procedure. SERVICE PROCEDURE A/C Condensate Leaks Into Passenger Compartment - Vehicles Built Prior To March, 1986 Due to improper condensate drainage, water can accumulate in the bottom of the temperature blend door frame assembly and spill into the blower housing. If this condition occurs, insufficient sealing at the blower housing to evaporator housing flange and at the blower scroll cover to blower housing may allow leakage into the passenger compartment from these areas. An accumulation of water in the blower housing may result in water being blown through the register ducts and register outlets. To correct the condition, one or more of the following service procedures should be initiated in the sequence listed. They are to be initiated on a customer complaint basis. NOTE: Operation of the blower at a lower speed than Hi will allow accumulated condensate to drain out the drain tube. Therefore, operation of the blower below HI where possible, or periodic reduction of the blower speed from HI, will significantly reduce moisture accumulation. Also, when comfort will allow, operation of the air conditioner in MAX A/C rather than NORM A/C will reduce condensate accumulation by reducing the humidity entering the vehicle. Econoline Vehicles With (Production) Aspirator Drain Tube Built After March, 1984 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 2848 Figure 22 Drain Tube Replacement (Refer to Figure 22) 1. Pull the aspirator air hose from the aspirator outlet drain tube assembly. 2. Remove the aspirator outlet drain tube assembly from the barbed connection of the plastic evaporator drain tube projecting inboard from the bottom of the housing. 3. Remove the plastic evaporator drain tube and seal attached to the bottom of the evaporator housing by removing the two attaching screws with a 5/16 inch socket. Replace existing drain tube with E5UZ-19858-B drain assembly shown in Figure 22. Apply silicone sealer to the seal surface to insure a complete seal. Install seal, drain tube and attaching screws. 4. Plug aspirator air hose with rubber cap 382443-S or similar and tape hose out of the way on the underside of evaporator housing. Econoline Vehicles With "Duck Bill" Drain Tube Built Prior to March, 1984 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 2849 Figure 23 "Duck Bill" Drain Tube Replacement 1. Remove the original drain tube located in the engine compartment on the bottom of the evaporator housing - two screws (Figure 23). Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 2850 Figure 24 2. Install the new check valve and drain tube assembly and retainer (service kit D6UZ-19858-B) using the two hex head 5/8 inch long, No. 10 screws provided (Figure 24). Note that the key tab fits into the slot towards the front of the vehicle. Two spring nuts are available in the kit, if required. 3. Apply a liberal bead of fillet of silicone sealer to both sides of the sealing surfaces to seal any air leak paths due to housing surface irregularities. Procedure For Inspection And Repair Of Evaporator/Blower Housing Flange And Cover Leaks Into Passenger Compartment Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 2851 Figure 25 1. If equipped with an EEC IV system module in front of blower housing, remove module cover and dash flange attaching screws and lay module aside (Figure 25). 2. Check the lower flange of the blower housing to evaporator housing seal and the OUTSIDE-RECIRC door shaft lower pivot for leaks by plugging the drain tube and placing the FUNCTION lever in MAX A/C. Then, pour a sufficient quantity of warm water through the RECIRC door opening until the water level is approximately 3/8 inch deep. If leakage is noted, drain housing and proceed to the next step. Otherwise, remove plug from drain tube, drain housing and proceed to Step 6. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 2852 Figure 25 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 2853 Figure 26 3. If leakage was noted from the bottom end of the OUTSIDE-RECIRC door shaft, blow compressed air around the end of the shaft area until thoroughly dry. Apply black silicone sealer, D6AZ-19562-A, liberally to cover completely the end of the shaft and boss to seal the area to the housing (Figure 26). If leakage was not noted from the evaporator core lower mounting screw, blow compressed air around the screw head until dry and apply black silicone sealer, D6AZ-19562-A, to cover the screw head (Figure 26). 4. If leakage was noted from the flange, remove the blower motor resistor connections and the blower scroll cover (Figure 25). Remove eight screws from the bottom and sides of the housing flange (two screws inside blower housing). Leave the top three screws in place, as well as the vacuum actuator shaft clip (Figure 26). 5. Pry the lower flanges of the blower and evaporator housing apart. Thoroughly blow dry the sealing areas with compressed air. Apply a continuous bead of black silicone rubber sealer on the sealing surfaces across the bottom flange and 1-1/2 inches up both sides (Figure 26). Carefully place flanges together and reassemble eight screws. Allow time for the sealer to set up and repeat leak test of Step 2. 6. Remove blower scroll cover and inspect blower housing cover seal for full contact impression with edge of blower housing. If full contact is not evident or seal is damaged, replace seal or repair skip areas with silicone sealer. 7. Reassemble blower scroll cover and electrical connections, and EEC IV system module (if so equipped). 8. Check for proper blower operation as described in the applicable Shop Manual. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 2854 Figure 27 Service Procedure NOTE: Prior to venturi tube installation, the evaporator housing sealing procedures and installation of the straight condensate drain tube as described in TSB 85-11-16 and TSB 86-9- 14, must be performed (Figure 27). (Do not install screen or drain tube in motor blower housing.) Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 2855 Figure 28 1. Remove the blower motor resistor connections from the blower scroll cover (Figure 28). 2. Remove the blower scroll cover (seven screws) and the blower motor (four screws) from the blower housing (push/pull the blower motor wire grommet toward the inside of the evaporator). 3. Set the A/C control to an A/C position. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 2856 Figure 29 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 2857 Figure 34 4. Fabricate template A as shown in Figure 34. Align the template in the blower scroll housing by aligning the template small hole with the screw hole and scribe the D shape hole on the plastic blower housing. Remove the template and drill two small holes in the housing (Figure 29) in the scribed area. Then, cut away the remaining plastic with a sharp X-acto knife. Be careful not to damage the blend door frame during drilling and cutting. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 2858 Figure 30 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 2859 Figure 35 5. Fabricate template B as shown in Figure 35 to properly locate the drain hole and insert it in the door frame assembly. Align the template notch with the lower rib as shown in Figure 30. 6. CAUTION: Insert a small section of scrap metal through the door opening and into the gap between the right side of the door frame assembly and the evaporator core face to prevent damage to the evaporator core during the following drilling operation. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 2860 Figure 30 7. Drill a small pilot hole at the location indicated by template B and then follow with a 1/4 inch drill being careful to ensure that the edge of the hole is flush with the bottom floor of the frame assembly and also to not damage the evaporator core. Remove the scrap metal piece and template B after drilling. See Figure 30. 8. Clean the evaporator floor with a suitable solvent and dry thoroughly. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 2861 Figure 31 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 2862 Figure 32 Figure 33 9. Install the deflector (E7UZ-19B898-A) in the evaporator housing by applying RTV sealant to the deflector flange, inserting it through the door opening, aligning it with the evaporator face and the door assembly and then firmly pressing the flange against the evaporator case floor until the sealant sets. See Figures 31 and 33. 10. Apply sealant to the flange of the venturi tube (E7UZ-18K368-A) and insert the tube through the hole made in Step 4. See Figure 33. Ensure that the tube end is aligned with the hole made in Step 7. Verify that a 1/8 inch gap exists between the bottom of the tube end and the housing wall for trapped condensate to exit. See Figure 33. If required, slot the screw hole. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 2863 11. Inspect the blower scroll cover seal for full contact impression with the edge of the blower housing. If full contact is not evident or the seal is damaged, replace the seal or repair the skipped areas with RTV sealer. 12. Reassemble the blower, blower scroll, electrical connections and check for proper blower operation as described in the applicable Shop Manual. Be sure that the blower motor wire grommet is pulled into the hole in the housing. PART NUMBER PART NAME CLASS E5UZ-19858-B Check Valve Assembly A Production Aspirator Drain Tube Built March, 1984 thru September, 1984 D6UZ-19858-B Check Valve Assembly B "Duck Bill" Drain Tube Built Prior to March, 1984 E7UZ-19B898-A Deflector C E7UZ-18K368-A Venturi C 382443-S Rubber Cap BS D6AZ-19562-A Silicone Sealer A OTHER APPLICABLE ARTICLES: 86-9-14, 85-11-16 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP19858A85 TIME: 1.2 Hrs. - Vehicles produced from 1975-84 (produced prior to March, 1984). 1.5 Hrs. - Vehicles produced from March, 1984. OPERATION: SP18424A86 - To be performed only after one of the above operations has been completed. TIME: 0.9 Hr. DLR. CODING: Basic Part No. 19858 - Code: 48 (Figures 22 through 35 on following pages) Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 86914 > May > 86 > A/C - Condensate Leakage Into Passenger Compartment Evaporator Case: Customer Interest A/C - Condensate Leakage Into Passenger Compartment Article No. 86-9-14 A/C CONDENSATE LEAKS INTO PASSENGER COMPARTMENT - VEHICLES BUILT PRIOR TO MARCH 1986 LIGHT TRUCK 1975-86 ECONOLINE When a vehicle is operated under conditions of extremely high humidity with the Function Selector Lever in the "NORM A/C" position and the blower switch in "HI", some evaporator condensate, instead of draining out of the vehicle, is being blown through the ducts and registers and into the passenger compartment. Condensate from the evaporator core exceeds the amount which can be drawn off through the drain tube in the evaporator case. As a result, the excess condensate can be pulled away from the drain tube and picked up in the air stream created by the blower motor. It is then expelled through the A/C registers. To correct the condition, one or more of the following service procedures should be initiated in the sequence listed. They are to be initiated on a customer complaint basis. Vehicles built prior to March, 1984 will continue to be serviced, as required, by all of the procedures covered in TSB 85-11-16 in addition to the procedures provided in this article. Complaints requiring service on vehicles built from March, 1984 to March, 1986 will be handled by following the sequence of procedures in this article. NOTE: Operation of the blower at a lower speed than HI will allow accumulated condensate to drain out the drain tube. Therefore, operation of the blower below HI where possible, or periodic reduction of the blower speed from HI, will significantly reduce moisture accumulation. Also, when comfort will allow, operation of the air conditioner in MAX A/C rather than NORM A/C will reduce condensate accumulation by reducing the humidity entering the vehicle. SERVICE PROCEDURE: 1. The sealing and leak checking procedures previously published in TSB 85-11-16, dated 6/3/85, must have already been performed, or should now be performed before proceeding with the added service operations covered in this article. 2. Replace the evaporator check valve and drain tube assembly (including the 90~ formed drain tube and check valve) with a new check valve and drain tube assembly. 3. If replacement of the evaporator drain tube assembly does not correct the condensate leak, add a separate drain hole in the blower housing as outlined under "Addition of Drain to Blower, Housing". 4. If the condition still persists, install a locally fabricated moisture coalescer screen as outlined under "Addition of Coalescer Screen to Evaporator Assembly". Sealing and Leak Checking Per TSB 85-11-16 1. Using TSB 85-11-16 as a guide, confirm that the sealing operations described have been effectively accomplished. 2. If sealing is missing, apply it to the surfaces indicated in the TSB. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 86914 > May > 86 > A/C - Condensate Leakage Into Passenger Compartment > Page 2868 Figure 7 Replacement of Evaporator Condensate Drain Tube Assembly - Vehicles Built From March, 1984 to March, 1986 Only (Refer to Figure 7) 1. Remove battery. 2. Pull the check valve drain tube assembly (includes 90~ formed hose and check valve) from the barbed end of the plastic drain tube projecting inboard from the bottom of the evaporator housing. 3. Remove the plastic evaporator drain tube and seal attached to the bottom of the evaporator housing by removing the two attaching screws with a 5/16 inch socket. Discard the drain tube parts and keep the screws. 4. Using a new seal, attach the new plastic drain tube to the bottom of the evaporator drain housing, using two No. 10-16 x .5 hex washer head screws (42367-S2) and two No. 10 spring nuts (Figure 7). No. 10-12 x .5 screws (42127-S2) may be used as an option to screws 42367-S2. 5. Push the new straight check valve drain hose onto the barbed end of the plastic drain tube with the check valve pointing straight down, Prior to installation, ensure that the check valve disc is free to move and check airflow. Conduct the check by blowing and drawing air through the hose. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 86914 > May > 86 > A/C - Condensate Leakage Into Passenger Compartment > Page 2869 Figure 8 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 86914 > May > 86 > A/C - Condensate Leakage Into Passenger Compartment > Page 2870 Figure 9 Addition of Drain to Blower Housing (Refer to Figures 8 and 9). Figure 7 Adding a drain to the blower housing must be performed only after (or in conjunction with) procedures for sealing of the housing and flanges as outlined in TSB 85-11-16 have been completed and the new straight check valve drain tube shown in Figure 7 has been installed. Failure to eliminate or minimize condensate carryover by following the procedures outlined in TSB 85-11-16 will result in exposing the blower motor to excessive amounts of water which will adversely affect motor life. 1. If equipped with an EEC IV system module in front of blower housing, remove the module cover and dash flange attaching screws and lay the module aside. 2. Remove the blower motor and resistor connections from the blower scroll cover. 3. Remove the blower scroll cover (7 screws) and blower motor (4 screws) from the blower housing (push/pull blower motor wire grommet toward inside of evaporator housing). Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 86914 > May > 86 > A/C - Condensate Leakage Into Passenger Compartment > Page 2871 Figure 9 4. Drill a 1/4 inch hole through the lowest corner of the blower housing, as shown in Figure 9. 5. Fabricate an eyelet from 1/4 inch tubing approximately 1 inch long. Insert the eyelet from the inside of the housing and seal around it completely with silicone sealer, or equivalent. 6. Drill a 3/8 inch hole through the dash panel 1 inch to the left of the EEC IV dash panel grommet if the EEC IV system is used. Drill it through the dash plug in the grommet hole if the EEC IV system is not used. 7. Attach a 1/4 inch ID by 8 inches long rubber hose to the eyelet and route it through the hole in the dash or dash plug. Seal the hose to the dash opening or dash plug, as applicable, with silicone sealer, or equivalent. 8. Reassemble the blower, blower scroll, and electrical connections and check for proper blower operation as described in the applicable Shop Manual. Be sure the blower motor wire grommet is pulled into the hole in housing. Addition of Coalescer Screen to Evaporator Assembly The coalescer screen provides a barrier and collecting surface for water droplets which are expelled from the evaporator core. The "U" shaped configuration in the direction of the airflow allows water to flow along the screen surface toward the edges of the blend door frame and downward to the bottom of the evaporator housing. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 86914 > May > 86 > A/C - Condensate Leakage Into Passenger Compartment > Page 2872 Figure 8 1. If equipped with an EEC IV system module in front of blower housing, remove the module cover and dash flange attaching screws and lay the module aside. (Figure 8) 2. Remove the blower motor and resistor connections from the blower scroll cover. (Figure 8) 3. Remove blower scroll cover (7 screws) and blower motor (4 screws) from the blower housing (push/ pull blower motor wire grommet toward inside of evaporator housing). (Figure 8) Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 86914 > May > 86 > A/C - Condensate Leakage Into Passenger Compartment > Page 2873 Figure 10 4. Fabricate the screen from a piece of 6-1/2 inch by 12-1/2 inch aluminum window screen, as shown in Figure 10. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Case: > 86914 > May > 86 > A/C - Condensate Leakage Into Passenger Compartment > Page 2874 Figure 11 5. Compress the "U" cross-section of screen slightly and push the screen through the blower opening and A/C side of blend door frame opening with "U" facing upwards. Once past the blend door frame opening, stand screen upright and pull edges toward the back side of the blend door frame and hold it against the edge of the evaporator core and heater core with sealer (or equivalent) as shown in Figure 11. 6. Check the temperature blend door for full travel and adjust it, if necessary, as described in the applicable Shop Manual. 7. Reassemble the blower, blower scroll, and electrical connections and check for proper blower operation as described in the applicable Shop Manual. Be sure the blower motor wire grommet is pulled into the hole in the housing. PART NUMBER PART NAME CLASS E6UZ-19858-A A/C Kit BG OTHER APPLICABLE ARTICLES: 85-11-16 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP19858A86 TIME: 0.5 Hr. - Replacement of Evaporator Condensate Drain Tube Assembly OPERATION: SP19858B86 TIME: 0.9 Hr. - Addition of Drain to Blower Housing and Addition of Coalescer Screen to Evaporator Assembly DLR. CODING: Basic Part No. 19858 - Code: 79 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment Evaporator Case: All Technical Service Bulletins A/C - Condensate Leaks Into Passenger Compartment Article No. 86-23-14 A/C CONDENSATE LEAKS INTO PASSENGER COMPARTMENT OR DISCHARGES FROM THE INSTRUMENT PANEL REGISTERS LIGHT TRUCK 1975-87 ECONOLINE Condensate may leak from the blower motor area or be expelled through the A/C registers during high temperature/high humidity conditions when the system is operated in Norm A/C and high blower. In these cases, condensate collects in the temperature blend door area and leaks out the seams of the blower case and/or becomes airborne and is expelled through the A/C registers. Check to assure that the evaporator housing has been sealed and the straight condensate drain tube has been installed as outlined in this article. Then, procure and install a new venturi tube and deflector in the evaporator assembly using the following service procedure. SERVICE PROCEDURE A/C Condensate Leaks Into Passenger Compartment - Vehicles Built Prior To March, 1986 Due to improper condensate drainage, water can accumulate in the bottom of the temperature blend door frame assembly and spill into the blower housing. If this condition occurs, insufficient sealing at the blower housing to evaporator housing flange and at the blower scroll cover to blower housing may allow leakage into the passenger compartment from these areas. An accumulation of water in the blower housing may result in water being blown through the register ducts and register outlets. To correct the condition, one or more of the following service procedures should be initiated in the sequence listed. They are to be initiated on a customer complaint basis. NOTE: Operation of the blower at a lower speed than Hi will allow accumulated condensate to drain out the drain tube. Therefore, operation of the blower below HI where possible, or periodic reduction of the blower speed from HI, will significantly reduce moisture accumulation. Also, when comfort will allow, operation of the air conditioner in MAX A/C rather than NORM A/C will reduce condensate accumulation by reducing the humidity entering the vehicle. Econoline Vehicles With (Production) Aspirator Drain Tube Built After March, 1984 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 2880 Figure 22 Drain Tube Replacement (Refer to Figure 22) 1. Pull the aspirator air hose from the aspirator outlet drain tube assembly. 2. Remove the aspirator outlet drain tube assembly from the barbed connection of the plastic evaporator drain tube projecting inboard from the bottom of the housing. 3. Remove the plastic evaporator drain tube and seal attached to the bottom of the evaporator housing by removing the two attaching screws with a 5/16 inch socket. Replace existing drain tube with E5UZ-19858-B drain assembly shown in Figure 22. Apply silicone sealer to the seal surface to insure a complete seal. Install seal, drain tube and attaching screws. 4. Plug aspirator air hose with rubber cap 382443-S or similar and tape hose out of the way on the underside of evaporator housing. Econoline Vehicles With "Duck Bill" Drain Tube Built Prior to March, 1984 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 2881 Figure 23 "Duck Bill" Drain Tube Replacement 1. Remove the original drain tube located in the engine compartment on the bottom of the evaporator housing - two screws (Figure 23). Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 2882 Figure 24 2. Install the new check valve and drain tube assembly and retainer (service kit D6UZ-19858-B) using the two hex head 5/8 inch long, No. 10 screws provided (Figure 24). Note that the key tab fits into the slot towards the front of the vehicle. Two spring nuts are available in the kit, if required. 3. Apply a liberal bead of fillet of silicone sealer to both sides of the sealing surfaces to seal any air leak paths due to housing surface irregularities. Procedure For Inspection And Repair Of Evaporator/Blower Housing Flange And Cover Leaks Into Passenger Compartment Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 2883 Figure 25 1. If equipped with an EEC IV system module in front of blower housing, remove module cover and dash flange attaching screws and lay module aside (Figure 25). 2. Check the lower flange of the blower housing to evaporator housing seal and the OUTSIDE-RECIRC door shaft lower pivot for leaks by plugging the drain tube and placing the FUNCTION lever in MAX A/C. Then, pour a sufficient quantity of warm water through the RECIRC door opening until the water level is approximately 3/8 inch deep. If leakage is noted, drain housing and proceed to the next step. Otherwise, remove plug from drain tube, drain housing and proceed to Step 6. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 2884 Figure 25 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 2885 Figure 26 3. If leakage was noted from the bottom end of the OUTSIDE-RECIRC door shaft, blow compressed air around the end of the shaft area until thoroughly dry. Apply black silicone sealer, D6AZ-19562-A, liberally to cover completely the end of the shaft and boss to seal the area to the housing (Figure 26). If leakage was not noted from the evaporator core lower mounting screw, blow compressed air around the screw head until dry and apply black silicone sealer, D6AZ-19562-A, to cover the screw head (Figure 26). 4. If leakage was noted from the flange, remove the blower motor resistor connections and the blower scroll cover (Figure 25). Remove eight screws from the bottom and sides of the housing flange (two screws inside blower housing). Leave the top three screws in place, as well as the vacuum actuator shaft clip (Figure 26). 5. Pry the lower flanges of the blower and evaporator housing apart. Thoroughly blow dry the sealing areas with compressed air. Apply a continuous bead of black silicone rubber sealer on the sealing surfaces across the bottom flange and 1-1/2 inches up both sides (Figure 26). Carefully place flanges together and reassemble eight screws. Allow time for the sealer to set up and repeat leak test of Step 2. 6. Remove blower scroll cover and inspect blower housing cover seal for full contact impression with edge of blower housing. If full contact is not evident or seal is damaged, replace seal or repair skip areas with silicone sealer. 7. Reassemble blower scroll cover and electrical connections, and EEC IV system module (if so equipped). 8. Check for proper blower operation as described in the applicable Shop Manual. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 2886 Figure 27 Service Procedure NOTE: Prior to venturi tube installation, the evaporator housing sealing procedures and installation of the straight condensate drain tube as described in TSB 85-11-16 and TSB 86-9- 14, must be performed (Figure 27). (Do not install screen or drain tube in motor blower housing.) Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 2887 Figure 28 1. Remove the blower motor resistor connections from the blower scroll cover (Figure 28). 2. Remove the blower scroll cover (seven screws) and the blower motor (four screws) from the blower housing (push/pull the blower motor wire grommet toward the inside of the evaporator). 3. Set the A/C control to an A/C position. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 2888 Figure 29 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 2889 Figure 34 4. Fabricate template A as shown in Figure 34. Align the template in the blower scroll housing by aligning the template small hole with the screw hole and scribe the D shape hole on the plastic blower housing. Remove the template and drill two small holes in the housing (Figure 29) in the scribed area. Then, cut away the remaining plastic with a sharp X-acto knife. Be careful not to damage the blend door frame during drilling and cutting. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 2890 Figure 30 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 2891 Figure 35 5. Fabricate template B as shown in Figure 35 to properly locate the drain hole and insert it in the door frame assembly. Align the template notch with the lower rib as shown in Figure 30. 6. CAUTION: Insert a small section of scrap metal through the door opening and into the gap between the right side of the door frame assembly and the evaporator core face to prevent damage to the evaporator core during the following drilling operation. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 2892 Figure 30 7. Drill a small pilot hole at the location indicated by template B and then follow with a 1/4 inch drill being careful to ensure that the edge of the hole is flush with the bottom floor of the frame assembly and also to not damage the evaporator core. Remove the scrap metal piece and template B after drilling. See Figure 30. 8. Clean the evaporator floor with a suitable solvent and dry thoroughly. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 2893 Figure 31 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 2894 Figure 32 Figure 33 9. Install the deflector (E7UZ-19B898-A) in the evaporator housing by applying RTV sealant to the deflector flange, inserting it through the door opening, aligning it with the evaporator face and the door assembly and then firmly pressing the flange against the evaporator case floor until the sealant sets. See Figures 31 and 33. 10. Apply sealant to the flange of the venturi tube (E7UZ-18K368-A) and insert the tube through the hole made in Step 4. See Figure 33. Ensure that the tube end is aligned with the hole made in Step 7. Verify that a 1/8 inch gap exists between the bottom of the tube end and the housing wall for trapped condensate to exit. See Figure 33. If required, slot the screw hole. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 862314 > Nov > 86 > A/C - Condensate Leaks Into Passenger Compartment > Page 2895 11. Inspect the blower scroll cover seal for full contact impression with the edge of the blower housing. If full contact is not evident or the seal is damaged, replace the seal or repair the skipped areas with RTV sealer. 12. Reassemble the blower, blower scroll, electrical connections and check for proper blower operation as described in the applicable Shop Manual. Be sure that the blower motor wire grommet is pulled into the hole in the housing. PART NUMBER PART NAME CLASS E5UZ-19858-B Check Valve Assembly A Production Aspirator Drain Tube Built March, 1984 thru September, 1984 D6UZ-19858-B Check Valve Assembly B "Duck Bill" Drain Tube Built Prior to March, 1984 E7UZ-19B898-A Deflector C E7UZ-18K368-A Venturi C 382443-S Rubber Cap BS D6AZ-19562-A Silicone Sealer A OTHER APPLICABLE ARTICLES: 86-9-14, 85-11-16 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP19858A85 TIME: 1.2 Hrs. - Vehicles produced from 1975-84 (produced prior to March, 1984). 1.5 Hrs. - Vehicles produced from March, 1984. OPERATION: SP18424A86 - To be performed only after one of the above operations has been completed. TIME: 0.9 Hr. DLR. CODING: Basic Part No. 19858 - Code: 48 (Figures 22 through 35 on following pages) Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 86914 > May > 86 > A/C - Condensate Leakage Into Passenger Compartment Evaporator Case: All Technical Service Bulletins A/C - Condensate Leakage Into Passenger Compartment Article No. 86-9-14 A/C CONDENSATE LEAKS INTO PASSENGER COMPARTMENT - VEHICLES BUILT PRIOR TO MARCH 1986 LIGHT TRUCK 1975-86 ECONOLINE When a vehicle is operated under conditions of extremely high humidity with the Function Selector Lever in the "NORM A/C" position and the blower switch in "HI", some evaporator condensate, instead of draining out of the vehicle, is being blown through the ducts and registers and into the passenger compartment. Condensate from the evaporator core exceeds the amount which can be drawn off through the drain tube in the evaporator case. As a result, the excess condensate can be pulled away from the drain tube and picked up in the air stream created by the blower motor. It is then expelled through the A/C registers. To correct the condition, one or more of the following service procedures should be initiated in the sequence listed. They are to be initiated on a customer complaint basis. Vehicles built prior to March, 1984 will continue to be serviced, as required, by all of the procedures covered in TSB 85-11-16 in addition to the procedures provided in this article. Complaints requiring service on vehicles built from March, 1984 to March, 1986 will be handled by following the sequence of procedures in this article. NOTE: Operation of the blower at a lower speed than HI will allow accumulated condensate to drain out the drain tube. Therefore, operation of the blower below HI where possible, or periodic reduction of the blower speed from HI, will significantly reduce moisture accumulation. Also, when comfort will allow, operation of the air conditioner in MAX A/C rather than NORM A/C will reduce condensate accumulation by reducing the humidity entering the vehicle. SERVICE PROCEDURE: 1. The sealing and leak checking procedures previously published in TSB 85-11-16, dated 6/3/85, must have already been performed, or should now be performed before proceeding with the added service operations covered in this article. 2. Replace the evaporator check valve and drain tube assembly (including the 90~ formed drain tube and check valve) with a new check valve and drain tube assembly. 3. If replacement of the evaporator drain tube assembly does not correct the condensate leak, add a separate drain hole in the blower housing as outlined under "Addition of Drain to Blower, Housing". 4. If the condition still persists, install a locally fabricated moisture coalescer screen as outlined under "Addition of Coalescer Screen to Evaporator Assembly". Sealing and Leak Checking Per TSB 85-11-16 1. Using TSB 85-11-16 as a guide, confirm that the sealing operations described have been effectively accomplished. 2. If sealing is missing, apply it to the surfaces indicated in the TSB. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 86914 > May > 86 > A/C - Condensate Leakage Into Passenger Compartment > Page 2900 Figure 7 Replacement of Evaporator Condensate Drain Tube Assembly - Vehicles Built From March, 1984 to March, 1986 Only (Refer to Figure 7) 1. Remove battery. 2. Pull the check valve drain tube assembly (includes 90~ formed hose and check valve) from the barbed end of the plastic drain tube projecting inboard from the bottom of the evaporator housing. 3. Remove the plastic evaporator drain tube and seal attached to the bottom of the evaporator housing by removing the two attaching screws with a 5/16 inch socket. Discard the drain tube parts and keep the screws. 4. Using a new seal, attach the new plastic drain tube to the bottom of the evaporator drain housing, using two No. 10-16 x .5 hex washer head screws (42367-S2) and two No. 10 spring nuts (Figure 7). No. 10-12 x .5 screws (42127-S2) may be used as an option to screws 42367-S2. 5. Push the new straight check valve drain hose onto the barbed end of the plastic drain tube with the check valve pointing straight down, Prior to installation, ensure that the check valve disc is free to move and check airflow. Conduct the check by blowing and drawing air through the hose. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 86914 > May > 86 > A/C - Condensate Leakage Into Passenger Compartment > Page 2901 Figure 8 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 86914 > May > 86 > A/C - Condensate Leakage Into Passenger Compartment > Page 2902 Figure 9 Addition of Drain to Blower Housing (Refer to Figures 8 and 9). Figure 7 Adding a drain to the blower housing must be performed only after (or in conjunction with) procedures for sealing of the housing and flanges as outlined in TSB 85-11-16 have been completed and the new straight check valve drain tube shown in Figure 7 has been installed. Failure to eliminate or minimize condensate carryover by following the procedures outlined in TSB 85-11-16 will result in exposing the blower motor to excessive amounts of water which will adversely affect motor life. 1. If equipped with an EEC IV system module in front of blower housing, remove the module cover and dash flange attaching screws and lay the module aside. 2. Remove the blower motor and resistor connections from the blower scroll cover. 3. Remove the blower scroll cover (7 screws) and blower motor (4 screws) from the blower housing (push/pull blower motor wire grommet toward inside of evaporator housing). Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 86914 > May > 86 > A/C - Condensate Leakage Into Passenger Compartment > Page 2903 Figure 9 4. Drill a 1/4 inch hole through the lowest corner of the blower housing, as shown in Figure 9. 5. Fabricate an eyelet from 1/4 inch tubing approximately 1 inch long. Insert the eyelet from the inside of the housing and seal around it completely with silicone sealer, or equivalent. 6. Drill a 3/8 inch hole through the dash panel 1 inch to the left of the EEC IV dash panel grommet if the EEC IV system is used. Drill it through the dash plug in the grommet hole if the EEC IV system is not used. 7. Attach a 1/4 inch ID by 8 inches long rubber hose to the eyelet and route it through the hole in the dash or dash plug. Seal the hose to the dash opening or dash plug, as applicable, with silicone sealer, or equivalent. 8. Reassemble the blower, blower scroll, and electrical connections and check for proper blower operation as described in the applicable Shop Manual. Be sure the blower motor wire grommet is pulled into the hole in housing. Addition of Coalescer Screen to Evaporator Assembly The coalescer screen provides a barrier and collecting surface for water droplets which are expelled from the evaporator core. The "U" shaped configuration in the direction of the airflow allows water to flow along the screen surface toward the edges of the blend door frame and downward to the bottom of the evaporator housing. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 86914 > May > 86 > A/C - Condensate Leakage Into Passenger Compartment > Page 2904 Figure 8 1. If equipped with an EEC IV system module in front of blower housing, remove the module cover and dash flange attaching screws and lay the module aside. (Figure 8) 2. Remove the blower motor and resistor connections from the blower scroll cover. (Figure 8) 3. Remove blower scroll cover (7 screws) and blower motor (4 screws) from the blower housing (push/ pull blower motor wire grommet toward inside of evaporator housing). (Figure 8) Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 86914 > May > 86 > A/C - Condensate Leakage Into Passenger Compartment > Page 2905 Figure 10 4. Fabricate the screen from a piece of 6-1/2 inch by 12-1/2 inch aluminum window screen, as shown in Figure 10. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 86914 > May > 86 > A/C - Condensate Leakage Into Passenger Compartment > Page 2906 Figure 11 5. Compress the "U" cross-section of screen slightly and push the screen through the blower opening and A/C side of blend door frame opening with "U" facing upwards. Once past the blend door frame opening, stand screen upright and pull edges toward the back side of the blend door frame and hold it against the edge of the evaporator core and heater core with sealer (or equivalent) as shown in Figure 11. 6. Check the temperature blend door for full travel and adjust it, if necessary, as described in the applicable Shop Manual. 7. Reassemble the blower, blower scroll, and electrical connections and check for proper blower operation as described in the applicable Shop Manual. Be sure the blower motor wire grommet is pulled into the hole in the housing. PART NUMBER PART NAME CLASS E6UZ-19858-A A/C Kit BG OTHER APPLICABLE ARTICLES: 85-11-16 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP19858A86 TIME: 0.5 Hr. - Replacement of Evaporator Condensate Drain Tube Assembly OPERATION: SP19858B86 TIME: 0.9 Hr. - Addition of Drain to Blower Housing and Addition of Coalescer Screen to Evaporator Assembly DLR. CODING: Basic Part No. 19858 - Code: 79 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 86914 > May > 86 > A/C - Condensate Leakage Into Passenger Compartment Evaporator Drain Tube: Customer Interest A/C - Condensate Leakage Into Passenger Compartment Article No. 86-9-14 A/C CONDENSATE LEAKS INTO PASSENGER COMPARTMENT - VEHICLES BUILT PRIOR TO MARCH 1986 LIGHT TRUCK 1975-86 ECONOLINE When a vehicle is operated under conditions of extremely high humidity with the Function Selector Lever in the "NORM A/C" position and the blower switch in "HI", some evaporator condensate, instead of draining out of the vehicle, is being blown through the ducts and registers and into the passenger compartment. Condensate from the evaporator core exceeds the amount which can be drawn off through the drain tube in the evaporator case. As a result, the excess condensate can be pulled away from the drain tube and picked up in the air stream created by the blower motor. It is then expelled through the A/C registers. To correct the condition, one or more of the following service procedures should be initiated in the sequence listed. They are to be initiated on a customer complaint basis. Vehicles built prior to March, 1984 will continue to be serviced, as required, by all of the procedures covered in TSB 85-11-16 in addition to the procedures provided in this article. Complaints requiring service on vehicles built from March, 1984 to March, 1986 will be handled by following the sequence of procedures in this article. NOTE: Operation of the blower at a lower speed than HI will allow accumulated condensate to drain out the drain tube. Therefore, operation of the blower below HI where possible, or periodic reduction of the blower speed from HI, will significantly reduce moisture accumulation. Also, when comfort will allow, operation of the air conditioner in MAX A/C rather than NORM A/C will reduce condensate accumulation by reducing the humidity entering the vehicle. SERVICE PROCEDURE: 1. The sealing and leak checking procedures previously published in TSB 85-11-16, dated 6/3/85, must have already been performed, or should now be performed before proceeding with the added service operations covered in this article. 2. Replace the evaporator check valve and drain tube assembly (including the 90~ formed drain tube and check valve) with a new check valve and drain tube assembly. 3. If replacement of the evaporator drain tube assembly does not correct the condensate leak, add a separate drain hole in the blower housing as outlined under "Addition of Drain to Blower, Housing". 4. If the condition still persists, install a locally fabricated moisture coalescer screen as outlined under "Addition of Coalescer Screen to Evaporator Assembly". Sealing and Leak Checking Per TSB 85-11-16 1. Using TSB 85-11-16 as a guide, confirm that the sealing operations described have been effectively accomplished. 2. If sealing is missing, apply it to the surfaces indicated in the TSB. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 86914 > May > 86 > A/C - Condensate Leakage Into Passenger Compartment > Page 2915 Figure 7 Replacement of Evaporator Condensate Drain Tube Assembly - Vehicles Built From March, 1984 to March, 1986 Only (Refer to Figure 7) 1. Remove battery. 2. Pull the check valve drain tube assembly (includes 90~ formed hose and check valve) from the barbed end of the plastic drain tube projecting inboard from the bottom of the evaporator housing. 3. Remove the plastic evaporator drain tube and seal attached to the bottom of the evaporator housing by removing the two attaching screws with a 5/16 inch socket. Discard the drain tube parts and keep the screws. 4. Using a new seal, attach the new plastic drain tube to the bottom of the evaporator drain housing, using two No. 10-16 x .5 hex washer head screws (42367-S2) and two No. 10 spring nuts (Figure 7). No. 10-12 x .5 screws (42127-S2) may be used as an option to screws 42367-S2. 5. Push the new straight check valve drain hose onto the barbed end of the plastic drain tube with the check valve pointing straight down, Prior to installation, ensure that the check valve disc is free to move and check airflow. Conduct the check by blowing and drawing air through the hose. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 86914 > May > 86 > A/C - Condensate Leakage Into Passenger Compartment > Page 2916 Figure 8 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 86914 > May > 86 > A/C - Condensate Leakage Into Passenger Compartment > Page 2917 Figure 9 Addition of Drain to Blower Housing (Refer to Figures 8 and 9). Figure 7 Adding a drain to the blower housing must be performed only after (or in conjunction with) procedures for sealing of the housing and flanges as outlined in TSB 85-11-16 have been completed and the new straight check valve drain tube shown in Figure 7 has been installed. Failure to eliminate or minimize condensate carryover by following the procedures outlined in TSB 85-11-16 will result in exposing the blower motor to excessive amounts of water which will adversely affect motor life. 1. If equipped with an EEC IV system module in front of blower housing, remove the module cover and dash flange attaching screws and lay the module aside. 2. Remove the blower motor and resistor connections from the blower scroll cover. 3. Remove the blower scroll cover (7 screws) and blower motor (4 screws) from the blower housing (push/pull blower motor wire grommet toward inside of evaporator housing). Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 86914 > May > 86 > A/C - Condensate Leakage Into Passenger Compartment > Page 2918 Figure 9 4. Drill a 1/4 inch hole through the lowest corner of the blower housing, as shown in Figure 9. 5. Fabricate an eyelet from 1/4 inch tubing approximately 1 inch long. Insert the eyelet from the inside of the housing and seal around it completely with silicone sealer, or equivalent. 6. Drill a 3/8 inch hole through the dash panel 1 inch to the left of the EEC IV dash panel grommet if the EEC IV system is used. Drill it through the dash plug in the grommet hole if the EEC IV system is not used. 7. Attach a 1/4 inch ID by 8 inches long rubber hose to the eyelet and route it through the hole in the dash or dash plug. Seal the hose to the dash opening or dash plug, as applicable, with silicone sealer, or equivalent. 8. Reassemble the blower, blower scroll, and electrical connections and check for proper blower operation as described in the applicable Shop Manual. Be sure the blower motor wire grommet is pulled into the hole in housing. Addition of Coalescer Screen to Evaporator Assembly The coalescer screen provides a barrier and collecting surface for water droplets which are expelled from the evaporator core. The "U" shaped configuration in the direction of the airflow allows water to flow along the screen surface toward the edges of the blend door frame and downward to the bottom of the evaporator housing. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 86914 > May > 86 > A/C - Condensate Leakage Into Passenger Compartment > Page 2919 Figure 8 1. If equipped with an EEC IV system module in front of blower housing, remove the module cover and dash flange attaching screws and lay the module aside. (Figure 8) 2. Remove the blower motor and resistor connections from the blower scroll cover. (Figure 8) 3. Remove blower scroll cover (7 screws) and blower motor (4 screws) from the blower housing (push/ pull blower motor wire grommet toward inside of evaporator housing). (Figure 8) Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 86914 > May > 86 > A/C - Condensate Leakage Into Passenger Compartment > Page 2920 Figure 10 4. Fabricate the screen from a piece of 6-1/2 inch by 12-1/2 inch aluminum window screen, as shown in Figure 10. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 86914 > May > 86 > A/C - Condensate Leakage Into Passenger Compartment > Page 2921 Figure 11 5. Compress the "U" cross-section of screen slightly and push the screen through the blower opening and A/C side of blend door frame opening with "U" facing upwards. Once past the blend door frame opening, stand screen upright and pull edges toward the back side of the blend door frame and hold it against the edge of the evaporator core and heater core with sealer (or equivalent) as shown in Figure 11. 6. Check the temperature blend door for full travel and adjust it, if necessary, as described in the applicable Shop Manual. 7. Reassemble the blower, blower scroll, and electrical connections and check for proper blower operation as described in the applicable Shop Manual. Be sure the blower motor wire grommet is pulled into the hole in the housing. PART NUMBER PART NAME CLASS E6UZ-19858-A A/C Kit BG OTHER APPLICABLE ARTICLES: 85-11-16 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP19858A86 TIME: 0.5 Hr. - Replacement of Evaporator Condensate Drain Tube Assembly OPERATION: SP19858B86 TIME: 0.9 Hr. - Addition of Drain to Blower Housing and Addition of Coalescer Screen to Evaporator Assembly DLR. CODING: Basic Part No. 19858 - Code: 79 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 851116 > Jun > 85 > A/C Evaporator Housing - Water Leaks to Interior Evaporator Drain Tube: Customer Interest A/C Evaporator Housing - Water Leaks to Interior Article No. 85-11-16 AIR CONDITIONING - INADEQUATE DRAINAGE FROM EVAPORATOR HOUSING LIGHT TRUCK 1975-85 ECONOLINE During conditions of high humidity and high blower operation, evaporator condensate leaks into the passenger compartment from the A/C blower housing, blower housing to evaporator housing flange and/or the A/C register outlets. The fundamental cause of this leakage is that the blower is located downstream of the evaporator core (draw through system), resulting in a negative housing pressure with respect to ambient. During this condition of negative pressure, air flow can be drawn through the drain tube into the housing opposing the flow of condensate drainage out of the drain tube. Also, air leakage into the housing because of insufficient drain tube sealing can cause this concern. Due to improper condensate drainage, water can accumulate in the bottom of the temperature blend door frame assembly and spill into the blower housing. If this condition occurs, insufficient sealing at the blower housing to evaporator housing flange and at the blower scroll cover to blower housing may allow leakage into the passenger compartment from these areas. An accumulation of water in the blower housing may result in water being blown through the register ducts and register outlets. PROCEDURE: Install the new check valve drain tube assembly which completely shuts off air flow through the drain tube, due to the negative pressure, yet allows water to drain freely under all housing negative pressures encountered in service. Due to manufacturing variations of evaporator assemblies, some units are more susceptible to condensate accumulation and will require rework of the blend door frame and may necessitate resealing the lower housing flange. The following three drain tube systems may be reworked as outlined in the following paragraphs. Figure 18 Econoline Vehicles with (Production) Aspirator Drain Tube Built March 1984 through September 1984 Drain Tube Replacement (Refer to Figure 18) Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 851116 > Jun > 85 > A/C Evaporator Housing - Water Leaks to Interior > Page 2926 1. Pull the aspirator air hose from the aspirator outlet drain tube assembly. 2. Remove the aspirator outlet drain tube assembly from the barbed connection of the plastic evaporator drain tube projecting inboard from the bottom of the housing. 3. Remove the plastic evaporator drain tube and seal attached to the bottom of the evaporator housing by removing the two attaching screws with a 5/16 inch socket. Inspect the plastic drain tube for cracks or chips from the barbs which would provide an air leak path. Inspect the seal for full sealing contact around the drain opening from the housing to the drain tube. If not properly sealed, replace seal or apply silicone sealer to the seal surface to insure a complete seal. Install seal, drain tube and attaching screws. 4. Plug aspirator air hose with rubber cap 382443-S or similar and tape hose out of the way on the underside of evaporator housing. 5. Install the new check valve drain tube assembly, E5UZ-19858-B, to the barbed end of the plastic drain tube projecting from the underside of the evaporator housing with the check valve down. Blend Door Frame Rework and Resealing of Lower Housing Flanges The plastic blend door frame assembly introduced to production in March 1984, requires the addition of drain holes to prevent the accumulation of water. Add holes as follows: Figure 19 1. Remove the blower motor and resistor connections from the blower scroll cover (Figure 19). 2. Remove blower scroll cover (7 screws) and blower motor (4 screws) from blower housing (push/pull blower motor wire grommet toward inside of evaporator housing) (Figure 19). Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 851116 > Jun > 85 > A/C Evaporator Housing - Water Leaks to Interior > Page 2927 Figure 20 3. Drill two 3/16 inch holes approximately 30~ downward at locations shown in Figure 20. Exercise caution when breaking through to prevent drilling holes through bottom of evaporator housing. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 851116 > Jun > 85 > A/C Evaporator Housing - Water Leaks to Interior > Page 2928 Figure 21 - BLOWER HOUSING FLANGE AND DOOR SHAFT SEALING 4. Check the lower flange of the blower housing to evaporator housing (Figure 21) for leaks by plugging drain tube and pouring a quantity of warm water into the blend door frame, through the blower motor opening, until the water level is approximately 3/8 inch deep. If leakage is noted, drain housing and proceed to the next step. Otherwise, remove plug from drain tube, drain housing and proceed to Step 8. 5. If leakage was noted from the bottom end of the OUTSIDE-RECIRC door shaft, blow compressed air around the end of the shaft area until thoroughly dry. Apply black silicone sealer, D6AZ-19562-A, liberally and completely over the end of the shaft and boss to seal the area to the housing (Figure 21). 6. If leakage was noted from the flange, remove 8 screws from the bottom and sides of the housing flange (2 screws inside blower housing). Leave the top 3 screws in place as well as the vacuum actuator shaft clip. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 851116 > Jun > 85 > A/C Evaporator Housing - Water Leaks to Interior > Page 2929 Figure 21 - BLOWER HOUSING FLANGE AND DOOR SHAFT SEALING 7. Pry the flange apart between the blend door frame and evaporator housing, and the flange between the blower housing and blend door housing/evaporator housing. Thoroughly blow dry the sealing areas with compressed air. Apply a continuous bead of black silicone rubber sealer on the sealing surfaces across the bottom flange and 1-1/2 inches up the sides of the three parts (Figure 21). Carefully place flanges together and reassemble 8 screws. Allow time for sealer to set up and repeat leak test of Step 4. 8. Check temperature blend door for full travel and adjust if necessary as described in the applicable shop manual. 9. Inspect blower scroll cover seal for full contact impression with edge of blower housing. If full contact is not evident or seal is damaged, replace seal or repair skip areas with silicone sealer. 10. Reassemble blower, blower scroll, and electrical connections and check for proper blower operation as described in the applicable shop manual. Be sure blower motor wire grommet is pulled into hole in housing. Figure 22 - "DUCK BILL" EVAPORATOR DRAIN TUBE-REMOVAL Econoline Vehicles with "Duck Bill" Drain Tube Built Prior to March 1984 "Duck Bill" Drain Tube Replacement Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 851116 > Jun > 85 > A/C Evaporator Housing - Water Leaks to Interior > Page 2930 1. Remove the original drain tube located in the engine compartment on the bottom of the evaporator housing - two screws (Figure 22). Figure 23 EVAPORATOR DRAIN TUBE INSTALLATION-ECONOLINE 2. Install the new check valve and drain tube assembly and retainer (service kit D6UZ-19858-B) using the two hex head 5/8 inch long, No. 10 screws provided (Figure23). Note that the key tab fits into the slot towards the front of the vehicle. Two spring nuts are available in the kit, if required. 3. Apply a liberal bead or fillet of silicone sealer to both sides of the sealing surfaces to seal any air leak paths due to housing surface irregularities. Procedure for Inspection and Repair of Evaporator/ Blower Housing Flange and Cover Leaks into Passenger Compartment Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 851116 > Jun > 85 > A/C Evaporator Housing - Water Leaks to Interior > Page 2931 Figure 19 1. If equipped with an EEC IV system module in front of blower housing, remove module cover and dash flange attaching screws and lay module aside (Figure 19). 2. Check the lower flange of the blower housing to evaporator housing seal and the OUTSIDE-RECIRC door shaft lower pivot for leaks by plugging the drain tube and placing the FUNCTION lever in MAX A/C. Then, pour a sufficient quantity of warm water through the RECIRC door opening until the water level is approximately 3/8 inch deep. If leakage is noted, drain housing and proceed to the next step. Otherwise, remove plug from drain tube, drain housing and proceed to Step 6. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 851116 > Jun > 85 > A/C Evaporator Housing - Water Leaks to Interior > Page 2932 Figure 21 - BLOWER HOUSING FLANGE AND DOOR SHAFT SEALING 3. If leakage was noted from the bottom end of the OUTSIDE-RECIRC door shaft, blow compressed air around the end of the shaft area until thoroughly dry. Apply black silicone sealer, D6AZ-19562-A, liberally to cover completely the end of the shaft and boss to seal the area to the housing (Figure 21). 4. If leakage was noted from the flange, remove the blower motor resistor connections and the blower housing motor cover (Figure 19). Remove 8 screws from the bottom and sides of the housing flange (2 screws inside blower housing). Leave the top 3 screws in place, as well as the vacuum actuator shaft clip (Figure 21). Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 851116 > Jun > 85 > A/C Evaporator Housing - Water Leaks to Interior > Page 2933 Figure 21 - BLOWER HOUSING FLANGE AND DOOR SHAFT SEALING 5. Pry the lower flanges of the blower and evaporator housing apart. Thoroughly blow dry the sealing areas with compressed air. Apply a continuous bead of black silicone rubber sealer on the sealing surfaces across the bottom flange and 1-1/2 inches up both sides (Figure 21). Carefully place flanges together and reassemble 8 screws. Allow time for the sealer to set up and repeat leak test of Step 2. 6. Remove blower scroll cover and inspect blower housing cover seal for full contact impression with edge of blower housing. If full contact is not evident or seal is damaged, replace seal or repair skip areas with silicone sealer. 7. Reassemble blower scroll cover and electrical connections, and EEC IV system module (if so equipped). 8. Check for proper blower operation as described in the applicable shop manual. Econoline Vehicles Built from 1975 through February 1984 Serviced with Aspirator Drain Tube Kit Per TSB 84-18-21-S Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Drain Tube: > 851116 > Jun > 85 > A/C Evaporator Housing - Water Leaks to Interior > Page 2934 Figure 24 - SERVICE ONLY CHECK VALVE DRAIN TUBE ASSEMBLY - INSTALLATION Drain Tube Replacement (Refer to Figure 24) 1. Pull the aspirator air hose from the aspirator drain tube. 2. Plug the aspirator air hose with rubber cap 382- 443-S or similar, and tape hose out of the way on the underside of the housing. 3. Remove the drain hose located in the engine compartment on the bottom of the evaporator housing - two screws. 4. Install the new check valve and drain tube assembly and retainer (service kit D6UZ-19858-B) using the two hex head 5/8 inch long, No. 10 screws provided. Note that the key tab fits into the slot towards the front of the vehicle. Two spring nuts are available in the kit, if required. 5. Apply a liberal bead or fillet of silicone sealer to both sides of the sealing surfaces to seal any air leak paths due to housing surface irregularities. 6. To inspect the passenger compartment for leaks and/or repair the evaporator/blower housing flange cover seals, refer to the procedures described after the "Duck Bill" drain tube replacement procedures. PART NUMBER PART NAME CLASS E5UZ-19858-B Check Valve Assy. A Production Aspirator Drain Tube Built March 1984 thru Sept. 1984 D6UZ-19858-B Check Valve Assy. B Duck Bill Drain Tube Built Prior to March 1984 D6UZ-19858-B Check Valve Assy. B Service Only Aspirator OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP19858A85 Vehicles Produced from 1975-84 (Produced prior to September 1984) TIME: 1.2 Hrs. OPERATION: SP19858A85 Vehicles Produced from 9/84 to Date TIME: 1.5 Hrs. DLR CODING: Basic Part No. 19858 - Code: 48 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 86914 > May > 86 > A/C - Condensate Leakage Into Passenger Compartment Evaporator Drain Tube: All Technical Service Bulletins A/C - Condensate Leakage Into Passenger Compartment Article No. 86-9-14 A/C CONDENSATE LEAKS INTO PASSENGER COMPARTMENT - VEHICLES BUILT PRIOR TO MARCH 1986 LIGHT TRUCK 1975-86 ECONOLINE When a vehicle is operated under conditions of extremely high humidity with the Function Selector Lever in the "NORM A/C" position and the blower switch in "HI", some evaporator condensate, instead of draining out of the vehicle, is being blown through the ducts and registers and into the passenger compartment. Condensate from the evaporator core exceeds the amount which can be drawn off through the drain tube in the evaporator case. As a result, the excess condensate can be pulled away from the drain tube and picked up in the air stream created by the blower motor. It is then expelled through the A/C registers. To correct the condition, one or more of the following service procedures should be initiated in the sequence listed. They are to be initiated on a customer complaint basis. Vehicles built prior to March, 1984 will continue to be serviced, as required, by all of the procedures covered in TSB 85-11-16 in addition to the procedures provided in this article. Complaints requiring service on vehicles built from March, 1984 to March, 1986 will be handled by following the sequence of procedures in this article. NOTE: Operation of the blower at a lower speed than HI will allow accumulated condensate to drain out the drain tube. Therefore, operation of the blower below HI where possible, or periodic reduction of the blower speed from HI, will significantly reduce moisture accumulation. Also, when comfort will allow, operation of the air conditioner in MAX A/C rather than NORM A/C will reduce condensate accumulation by reducing the humidity entering the vehicle. SERVICE PROCEDURE: 1. The sealing and leak checking procedures previously published in TSB 85-11-16, dated 6/3/85, must have already been performed, or should now be performed before proceeding with the added service operations covered in this article. 2. Replace the evaporator check valve and drain tube assembly (including the 90~ formed drain tube and check valve) with a new check valve and drain tube assembly. 3. If replacement of the evaporator drain tube assembly does not correct the condensate leak, add a separate drain hole in the blower housing as outlined under "Addition of Drain to Blower, Housing". 4. If the condition still persists, install a locally fabricated moisture coalescer screen as outlined under "Addition of Coalescer Screen to Evaporator Assembly". Sealing and Leak Checking Per TSB 85-11-16 1. Using TSB 85-11-16 as a guide, confirm that the sealing operations described have been effectively accomplished. 2. If sealing is missing, apply it to the surfaces indicated in the TSB. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 86914 > May > 86 > A/C - Condensate Leakage Into Passenger Compartment > Page 2940 Figure 7 Replacement of Evaporator Condensate Drain Tube Assembly - Vehicles Built From March, 1984 to March, 1986 Only (Refer to Figure 7) 1. Remove battery. 2. Pull the check valve drain tube assembly (includes 90~ formed hose and check valve) from the barbed end of the plastic drain tube projecting inboard from the bottom of the evaporator housing. 3. Remove the plastic evaporator drain tube and seal attached to the bottom of the evaporator housing by removing the two attaching screws with a 5/16 inch socket. Discard the drain tube parts and keep the screws. 4. Using a new seal, attach the new plastic drain tube to the bottom of the evaporator drain housing, using two No. 10-16 x .5 hex washer head screws (42367-S2) and two No. 10 spring nuts (Figure 7). No. 10-12 x .5 screws (42127-S2) may be used as an option to screws 42367-S2. 5. Push the new straight check valve drain hose onto the barbed end of the plastic drain tube with the check valve pointing straight down, Prior to installation, ensure that the check valve disc is free to move and check airflow. Conduct the check by blowing and drawing air through the hose. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 86914 > May > 86 > A/C - Condensate Leakage Into Passenger Compartment > Page 2941 Figure 8 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 86914 > May > 86 > A/C - Condensate Leakage Into Passenger Compartment > Page 2942 Figure 9 Addition of Drain to Blower Housing (Refer to Figures 8 and 9). Figure 7 Adding a drain to the blower housing must be performed only after (or in conjunction with) procedures for sealing of the housing and flanges as outlined in TSB 85-11-16 have been completed and the new straight check valve drain tube shown in Figure 7 has been installed. Failure to eliminate or minimize condensate carryover by following the procedures outlined in TSB 85-11-16 will result in exposing the blower motor to excessive amounts of water which will adversely affect motor life. 1. If equipped with an EEC IV system module in front of blower housing, remove the module cover and dash flange attaching screws and lay the module aside. 2. Remove the blower motor and resistor connections from the blower scroll cover. 3. Remove the blower scroll cover (7 screws) and blower motor (4 screws) from the blower housing (push/pull blower motor wire grommet toward inside of evaporator housing). Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 86914 > May > 86 > A/C - Condensate Leakage Into Passenger Compartment > Page 2943 Figure 9 4. Drill a 1/4 inch hole through the lowest corner of the blower housing, as shown in Figure 9. 5. Fabricate an eyelet from 1/4 inch tubing approximately 1 inch long. Insert the eyelet from the inside of the housing and seal around it completely with silicone sealer, or equivalent. 6. Drill a 3/8 inch hole through the dash panel 1 inch to the left of the EEC IV dash panel grommet if the EEC IV system is used. Drill it through the dash plug in the grommet hole if the EEC IV system is not used. 7. Attach a 1/4 inch ID by 8 inches long rubber hose to the eyelet and route it through the hole in the dash or dash plug. Seal the hose to the dash opening or dash plug, as applicable, with silicone sealer, or equivalent. 8. Reassemble the blower, blower scroll, and electrical connections and check for proper blower operation as described in the applicable Shop Manual. Be sure the blower motor wire grommet is pulled into the hole in housing. Addition of Coalescer Screen to Evaporator Assembly The coalescer screen provides a barrier and collecting surface for water droplets which are expelled from the evaporator core. The "U" shaped configuration in the direction of the airflow allows water to flow along the screen surface toward the edges of the blend door frame and downward to the bottom of the evaporator housing. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 86914 > May > 86 > A/C - Condensate Leakage Into Passenger Compartment > Page 2944 Figure 8 1. If equipped with an EEC IV system module in front of blower housing, remove the module cover and dash flange attaching screws and lay the module aside. (Figure 8) 2. Remove the blower motor and resistor connections from the blower scroll cover. (Figure 8) 3. Remove blower scroll cover (7 screws) and blower motor (4 screws) from the blower housing (push/ pull blower motor wire grommet toward inside of evaporator housing). (Figure 8) Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 86914 > May > 86 > A/C - Condensate Leakage Into Passenger Compartment > Page 2945 Figure 10 4. Fabricate the screen from a piece of 6-1/2 inch by 12-1/2 inch aluminum window screen, as shown in Figure 10. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 86914 > May > 86 > A/C - Condensate Leakage Into Passenger Compartment > Page 2946 Figure 11 5. Compress the "U" cross-section of screen slightly and push the screen through the blower opening and A/C side of blend door frame opening with "U" facing upwards. Once past the blend door frame opening, stand screen upright and pull edges toward the back side of the blend door frame and hold it against the edge of the evaporator core and heater core with sealer (or equivalent) as shown in Figure 11. 6. Check the temperature blend door for full travel and adjust it, if necessary, as described in the applicable Shop Manual. 7. Reassemble the blower, blower scroll, and electrical connections and check for proper blower operation as described in the applicable Shop Manual. Be sure the blower motor wire grommet is pulled into the hole in the housing. PART NUMBER PART NAME CLASS E6UZ-19858-A A/C Kit BG OTHER APPLICABLE ARTICLES: 85-11-16 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP19858A86 TIME: 0.5 Hr. - Replacement of Evaporator Condensate Drain Tube Assembly OPERATION: SP19858B86 TIME: 0.9 Hr. - Addition of Drain to Blower Housing and Addition of Coalescer Screen to Evaporator Assembly DLR. CODING: Basic Part No. 19858 - Code: 79 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 851116 > Jun > 85 > A/C Evaporator Housing - Water Leaks to Interior Evaporator Drain Tube: All Technical Service Bulletins A/C Evaporator Housing - Water Leaks to Interior Article No. 85-11-16 AIR CONDITIONING - INADEQUATE DRAINAGE FROM EVAPORATOR HOUSING LIGHT TRUCK 1975-85 ECONOLINE During conditions of high humidity and high blower operation, evaporator condensate leaks into the passenger compartment from the A/C blower housing, blower housing to evaporator housing flange and/or the A/C register outlets. The fundamental cause of this leakage is that the blower is located downstream of the evaporator core (draw through system), resulting in a negative housing pressure with respect to ambient. During this condition of negative pressure, air flow can be drawn through the drain tube into the housing opposing the flow of condensate drainage out of the drain tube. Also, air leakage into the housing because of insufficient drain tube sealing can cause this concern. Due to improper condensate drainage, water can accumulate in the bottom of the temperature blend door frame assembly and spill into the blower housing. If this condition occurs, insufficient sealing at the blower housing to evaporator housing flange and at the blower scroll cover to blower housing may allow leakage into the passenger compartment from these areas. An accumulation of water in the blower housing may result in water being blown through the register ducts and register outlets. PROCEDURE: Install the new check valve drain tube assembly which completely shuts off air flow through the drain tube, due to the negative pressure, yet allows water to drain freely under all housing negative pressures encountered in service. Due to manufacturing variations of evaporator assemblies, some units are more susceptible to condensate accumulation and will require rework of the blend door frame and may necessitate resealing the lower housing flange. The following three drain tube systems may be reworked as outlined in the following paragraphs. Figure 18 Econoline Vehicles with (Production) Aspirator Drain Tube Built March 1984 through September 1984 Drain Tube Replacement (Refer to Figure 18) Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 851116 > Jun > 85 > A/C Evaporator Housing - Water Leaks to Interior > Page 2951 1. Pull the aspirator air hose from the aspirator outlet drain tube assembly. 2. Remove the aspirator outlet drain tube assembly from the barbed connection of the plastic evaporator drain tube projecting inboard from the bottom of the housing. 3. Remove the plastic evaporator drain tube and seal attached to the bottom of the evaporator housing by removing the two attaching screws with a 5/16 inch socket. Inspect the plastic drain tube for cracks or chips from the barbs which would provide an air leak path. Inspect the seal for full sealing contact around the drain opening from the housing to the drain tube. If not properly sealed, replace seal or apply silicone sealer to the seal surface to insure a complete seal. Install seal, drain tube and attaching screws. 4. Plug aspirator air hose with rubber cap 382443-S or similar and tape hose out of the way on the underside of evaporator housing. 5. Install the new check valve drain tube assembly, E5UZ-19858-B, to the barbed end of the plastic drain tube projecting from the underside of the evaporator housing with the check valve down. Blend Door Frame Rework and Resealing of Lower Housing Flanges The plastic blend door frame assembly introduced to production in March 1984, requires the addition of drain holes to prevent the accumulation of water. Add holes as follows: Figure 19 1. Remove the blower motor and resistor connections from the blower scroll cover (Figure 19). 2. Remove blower scroll cover (7 screws) and blower motor (4 screws) from blower housing (push/pull blower motor wire grommet toward inside of evaporator housing) (Figure 19). Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 851116 > Jun > 85 > A/C Evaporator Housing - Water Leaks to Interior > Page 2952 Figure 20 3. Drill two 3/16 inch holes approximately 30~ downward at locations shown in Figure 20. Exercise caution when breaking through to prevent drilling holes through bottom of evaporator housing. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 851116 > Jun > 85 > A/C Evaporator Housing - Water Leaks to Interior > Page 2953 Figure 21 - BLOWER HOUSING FLANGE AND DOOR SHAFT SEALING 4. Check the lower flange of the blower housing to evaporator housing (Figure 21) for leaks by plugging drain tube and pouring a quantity of warm water into the blend door frame, through the blower motor opening, until the water level is approximately 3/8 inch deep. If leakage is noted, drain housing and proceed to the next step. Otherwise, remove plug from drain tube, drain housing and proceed to Step 8. 5. If leakage was noted from the bottom end of the OUTSIDE-RECIRC door shaft, blow compressed air around the end of the shaft area until thoroughly dry. Apply black silicone sealer, D6AZ-19562-A, liberally and completely over the end of the shaft and boss to seal the area to the housing (Figure 21). 6. If leakage was noted from the flange, remove 8 screws from the bottom and sides of the housing flange (2 screws inside blower housing). Leave the top 3 screws in place as well as the vacuum actuator shaft clip. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 851116 > Jun > 85 > A/C Evaporator Housing - Water Leaks to Interior > Page 2954 Figure 21 - BLOWER HOUSING FLANGE AND DOOR SHAFT SEALING 7. Pry the flange apart between the blend door frame and evaporator housing, and the flange between the blower housing and blend door housing/evaporator housing. Thoroughly blow dry the sealing areas with compressed air. Apply a continuous bead of black silicone rubber sealer on the sealing surfaces across the bottom flange and 1-1/2 inches up the sides of the three parts (Figure 21). Carefully place flanges together and reassemble 8 screws. Allow time for sealer to set up and repeat leak test of Step 4. 8. Check temperature blend door for full travel and adjust if necessary as described in the applicable shop manual. 9. Inspect blower scroll cover seal for full contact impression with edge of blower housing. If full contact is not evident or seal is damaged, replace seal or repair skip areas with silicone sealer. 10. Reassemble blower, blower scroll, and electrical connections and check for proper blower operation as described in the applicable shop manual. Be sure blower motor wire grommet is pulled into hole in housing. Figure 22 - "DUCK BILL" EVAPORATOR DRAIN TUBE-REMOVAL Econoline Vehicles with "Duck Bill" Drain Tube Built Prior to March 1984 "Duck Bill" Drain Tube Replacement Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 851116 > Jun > 85 > A/C Evaporator Housing - Water Leaks to Interior > Page 2955 1. Remove the original drain tube located in the engine compartment on the bottom of the evaporator housing - two screws (Figure 22). Figure 23 EVAPORATOR DRAIN TUBE INSTALLATION-ECONOLINE 2. Install the new check valve and drain tube assembly and retainer (service kit D6UZ-19858-B) using the two hex head 5/8 inch long, No. 10 screws provided (Figure23). Note that the key tab fits into the slot towards the front of the vehicle. Two spring nuts are available in the kit, if required. 3. Apply a liberal bead or fillet of silicone sealer to both sides of the sealing surfaces to seal any air leak paths due to housing surface irregularities. Procedure for Inspection and Repair of Evaporator/ Blower Housing Flange and Cover Leaks into Passenger Compartment Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 851116 > Jun > 85 > A/C Evaporator Housing - Water Leaks to Interior > Page 2956 Figure 19 1. If equipped with an EEC IV system module in front of blower housing, remove module cover and dash flange attaching screws and lay module aside (Figure 19). 2. Check the lower flange of the blower housing to evaporator housing seal and the OUTSIDE-RECIRC door shaft lower pivot for leaks by plugging the drain tube and placing the FUNCTION lever in MAX A/C. Then, pour a sufficient quantity of warm water through the RECIRC door opening until the water level is approximately 3/8 inch deep. If leakage is noted, drain housing and proceed to the next step. Otherwise, remove plug from drain tube, drain housing and proceed to Step 6. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 851116 > Jun > 85 > A/C Evaporator Housing - Water Leaks to Interior > Page 2957 Figure 21 - BLOWER HOUSING FLANGE AND DOOR SHAFT SEALING 3. If leakage was noted from the bottom end of the OUTSIDE-RECIRC door shaft, blow compressed air around the end of the shaft area until thoroughly dry. Apply black silicone sealer, D6AZ-19562-A, liberally to cover completely the end of the shaft and boss to seal the area to the housing (Figure 21). 4. If leakage was noted from the flange, remove the blower motor resistor connections and the blower housing motor cover (Figure 19). Remove 8 screws from the bottom and sides of the housing flange (2 screws inside blower housing). Leave the top 3 screws in place, as well as the vacuum actuator shaft clip (Figure 21). Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 851116 > Jun > 85 > A/C Evaporator Housing - Water Leaks to Interior > Page 2958 Figure 21 - BLOWER HOUSING FLANGE AND DOOR SHAFT SEALING 5. Pry the lower flanges of the blower and evaporator housing apart. Thoroughly blow dry the sealing areas with compressed air. Apply a continuous bead of black silicone rubber sealer on the sealing surfaces across the bottom flange and 1-1/2 inches up both sides (Figure 21). Carefully place flanges together and reassemble 8 screws. Allow time for the sealer to set up and repeat leak test of Step 2. 6. Remove blower scroll cover and inspect blower housing cover seal for full contact impression with edge of blower housing. If full contact is not evident or seal is damaged, replace seal or repair skip areas with silicone sealer. 7. Reassemble blower scroll cover and electrical connections, and EEC IV system module (if so equipped). 8. Check for proper blower operation as described in the applicable shop manual. Econoline Vehicles Built from 1975 through February 1984 Serviced with Aspirator Drain Tube Kit Per TSB 84-18-21-S Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 851116 > Jun > 85 > A/C Evaporator Housing - Water Leaks to Interior > Page 2959 Figure 24 - SERVICE ONLY CHECK VALVE DRAIN TUBE ASSEMBLY - INSTALLATION Drain Tube Replacement (Refer to Figure 24) 1. Pull the aspirator air hose from the aspirator drain tube. 2. Plug the aspirator air hose with rubber cap 382- 443-S or similar, and tape hose out of the way on the underside of the housing. 3. Remove the drain hose located in the engine compartment on the bottom of the evaporator housing - two screws. 4. Install the new check valve and drain tube assembly and retainer (service kit D6UZ-19858-B) using the two hex head 5/8 inch long, No. 10 screws provided. Note that the key tab fits into the slot towards the front of the vehicle. Two spring nuts are available in the kit, if required. 5. Apply a liberal bead or fillet of silicone sealer to both sides of the sealing surfaces to seal any air leak paths due to housing surface irregularities. 6. To inspect the passenger compartment for leaks and/or repair the evaporator/blower housing flange cover seals, refer to the procedures described after the "Duck Bill" drain tube replacement procedures. PART NUMBER PART NAME CLASS E5UZ-19858-B Check Valve Assy. A Production Aspirator Drain Tube Built March 1984 thru Sept. 1984 D6UZ-19858-B Check Valve Assy. B Duck Bill Drain Tube Built Prior to March 1984 D6UZ-19858-B Check Valve Assy. B Service Only Aspirator OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SP19858A85 Vehicles Produced from 1975-84 (Produced prior to September 1984) TIME: 1.2 Hrs. OPERATION: SP19858A85 Vehicles Produced from 9/84 to Date TIME: 1.5 Hrs. DLR CODING: Basic Part No. 19858 - Code: 48 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations A/C EVAPORATOR DE-ICING SWITCH RH Dash Panel Attached To Evaporator Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Control Valve > Component Information > Locations Heater Control Valve: Locations Rear Of Engine Compartment Above RH Rear Side Of Engine Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Heater Core - Leakage Diagnostic Tips Heater Core: Technical Service Bulletins Heater Core - Leakage Diagnostic Tips Article No. 85-8-2 HEATER CORE - LEAK - DIAGNOSTIC TIPS FORD ALL LINCOLN-MERCURY ALL LIGHT TRUCK ALL Good heater cores are being returned through the parts return system coded as leaking. Complaints of leaking may be caused by an inadequate seal between the heater hose and the heater core tubes allowing coolant to follow the tube to the heater core, leak into the passenger compartment and appear as a leaking heater core. When diagnosing a suspect heater core leak, inspect the hose to heater core tube attachment to assure the connection is not leaking. If a leaking connection is found, correct the leak. If the connection appears not to be leaking, leak test the heater core before removing it from the vehicle using the following procedure: HEATER CORE LEAK TEST Pressure Test 1. Drain the coolant from the cooling system. 2. Disconnect the heater hoses from the heater core tubes. 3. Install a short piece of heater hose (approximately 4 inches long) on each heater core tube. Figure 1 4. Fill the heater core and hoses with water and install plug BT-7422-B and adapter BT-7422-A from Rotunda model 021-00012 or equivalent in the hose ends (Figure 1). Secure the hoses, plug and adapter with hose clamps. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Heater Core - Leakage Diagnostic Tips > Page 2970 Figure 2 Figure 3 - TOOL 021-00012 WITH HEATER HOSE AND CLAMPS 5. Attach the pump and gauge assembly Rotunda model 021-00012 or equivalent to the adapter (Figure 2). Close the bleed valve at the base of the gauge and pump 30 psi of air pressure into the heater core (Figure 3). 6. Observe the pressure gauge for a minimum of three minutes. The pressure should not drop. 7. If the pressure does not drop, no leaks are indicated. 8. If the pressure drops, check the hose connections to the core tubes for leaks. If the hoses do not leak, remove the heater core from the vehicle and perform the bench test. Bench Test 1. Drain all coolant from the heater core. Figure 4 - HEATER CORE BENCH TEST 2. Connect the 4-inch test hoses with plug and adapter to the core tubes. Then connect the air pump and gauge assembly to the adapter (Figure 4). 3. Apply 30 psi of air pressure to the heater core with Rotunda model 021-00012 or equivalent, and submerge the core in water. 4. If a leak is observed, service or replace the heater core as necessary. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Heater Core - Leakage Diagnostic Tips > Page 2971 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 2972 Heater Core: Service and Repair Less Air Conditioning Fig. 11 Heater core replacement. E-100---350 less air conditioning 1. Disconnect battery ground cable. On models equipped with dual batteries, disconnect both negative cables. Remove RH battery from vehicle. 2. Drain cooling system. 3. Disconnect resistor electrical connector, then the blower motor lead wire from wiring harness. 4. Remove ground wire attaching screw from dash. 5. Disconnect hoses from heater core, then remove plastic wrap securing hoses to heater assembly. 6. Remove 5 heater assembly attaching screws from passenger compartment, then lift heater assembly out of engine compartment. 7. Remove seal and retainer from front of heater core case, then slide core and seal out of case. 8. Reverse procedure to install. W/Air Conditioning Fig. 12 Heater core replacement. E-100---350 w/air conditioning 1. Disconnect battery ground cable. On models equipped with dual batteries, disconnect both negative cables. Remove RH battery from vehicle. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 2973 2. Disconnect electrical connector from resistor on front of air conditioner blower scroll cover. 3. Disconnect vacuum hose from outside recirculated door vacuum motor. 4. Remove air conditioner blower cover attaching screws and the cover. 5. Remove outside-recirculated door shaft push nut and washer. 6. Remove control cable attaching screw and slide cable over bracket. 7. Remove cable clip or wire loop from blend door shaft. 8. Remove 9 air conditioner blower motor housing attaching screws and the housing. 9. Remove 3 blend door housing attaching screws and the housing. 10. Drain cooling system, then disconnect hoses from heater core. 11. Remove 2 heater core retaining bracket attaching screws and the bracket. 12. Remove heater core and seal assembly. 13. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > Heater Damper Door - Service Part Information Housing Assembly HVAC: Technical Service Bulletins Heater Damper Door - Service Part Information AIR CONDITIONING-HEATER DAMPER DOOR AND HOUSING ASSEMBLY-SERVICE PART INFORMATION Article No. 89-11-9 Figure 1 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > Heater Damper Door - Service Part Information > Page 2978 Figure 2 LIGHT TRUCK: 1975-84 ECONOLINE ISSUE: The air conditioning/heater damper door and housing assembly to service 1975 through 1984 Econolines are no longer available for service. A new design air conditioning/heater damper door and housing assembly replaces the old design. The new assembly can be used on older Econolines if a few minor changes are made. ACTION: If service is required on an older Econoline, use the new air conditioning/heater damper door and housing assembly. Refer to the following procedure for service installation details. 1. Trim the flange off three (3) sides of the door frame as shown in Figure 1. 2. Position the template shown in Figure 2 on the door frame. 3. Drill two (2) holes in the bottom of the door frame for attaching it to the housing assembly. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Technical Service Bulletins > Heater Damper Door - Service Part Information > Page 2979 4. Attach the door frame to the housing assembly with two (2) 1/4 inch (6.35 mm) screws. PART NUMBER PART NAME CLASS E4UZ-18D293-A A/C-Heater Damper Door And C Housing OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2610 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement Technical Service Bulletin # 98-12-5 Date: 980622 A/C - Filtering Refrigerant After Compressor Replacement Article No. 98-12-5 06/22/98 AIR CONDITIONING - FILTERING REFRIGERANT AFTER A/C COMPRESSOR REPLACEMENT - SERVICE TIPS FORD: 1980-98 CROWN VICTORIA 1981-98 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-97 THUNDERBIRD 1982-98 MUSTANG 1983-86 LTD 1984-94 TEMPO 1986-98 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-98 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1980-98 GRAND MARQUIS, TOWN CAR 1982-83 ZEPHYR 1982-86 CAPRI 1982-87 LN7 1982-97 COUGAR 1982-98 CONTINENTAL 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-98 SABLE 1991-94 CAPRI 1991-98 TRACER 1993-98 MARK VIII 1995-98-MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1980-96 BRONCO 1980-97 F SUPER DUTY 1980-98 ECONOLINE, F-150, F-150, F-350 1983-98 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F-47 1991-98 EXPLORER 1993-98 VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to revise the Service Procedure and to update the model years. ISSUE Vehicles that have and inoperative A/C compressor, due to internal causes, MUST have the refrigerant system cleaned to remove any debris or contaminants that may be present to prevent damage to the replacement compressor. ACTION Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 2984 Install a Service Filter Kit in the refrigerant system prior to installing the replacement compressor. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-15-5 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-99 Models And 1991 Lincolns, Basic Warranty Coverage For All Other Models And Major Component Warranty Coverage For All Other Lincoins OPERATION DESCRIPTION TIME 981205A Kit Installation 1.2 Hrs. 981205B Extra Time For Refrigerant 0.4 Hr. (R-12) Recovery DEALER CODING CONDITION BASIC PART NO. CODE 19703 49 OASIS CODES: 208000, 208999 Service Procedure THIS PROCEDURE IS OPTIONAL IF THE SYSTEM IS FLUSHED USING THE ROTUNDA A/C FLUSHER. CAUTION THIS FILTERING PROCEDURE MAY BE USED FOR EITHER R-12 OR R-134a REFRIGERANT SYSTEMS. BECAUSE THE TWO (2) SYSTEMS USE DIFFERENT REFRIGERANT OILS AND BECAUSE THE COMPRESSOR COULD BE DAMAGED IF THE WRONG OIL IS USED, SYSTEM IDENTIFICATION IS VERY IMPORTANT. BE SURE SYSTEM IS CORRECTLY IDENTIFIED BEFORE STARTING THE FILTERING PROCEDURE. Each Service Filter Kit includes the following items: ^ One (1) Pancake Filter (to be installed in the liquid line between the condenser and the orifice tube) ^ One (1) Instruction Sheet NOTE ON 1993-94 RANGER/EXPLORER VEHICLES, TECHNICIANS MAY EXPERIENCE DIFFICULTY WHEN CONNECTING THE PANCAKE FILTER HOSE FITTINGS TO THE EVAPORATOR INLET WITH THE ORIFICE TUBE INSTALLED. REMOVE THE OFFICE TUBE AND RUN THE SYSTEM FOR 1 HOUR AS DESCRIBED IN THE FILTERING PROCEDURE. REINSTALL THE ORIFICE TUBE AFTER FILTERING IS COMPLETE. CAUTION FOLLOW ALL REFRIGERANT SYSTEM SAFETY AND SERVICE PRECAUTIONS OUTLINED IN THE APPROPRIATE SERVICE OR WORKSHOP MANUAL. 1. Before removing any refrigerant system components, recover the refrigerant from the system following the recycling methods outlined In the appropriate Service/Workshop Manual. 2. Remove the suction accumulator/drier assembly and drain the oil into a calibrated container. 3. Install a new suction accumulator/drier and add new refrigerant oil to replace the old oil. The quantity of the new oil to be added is the amount to match that drained from the old accumulator plus 60 mL (2 oz). Refer to the Dealer Master Parts Catalog for the correct suction accumulator/drier part number. CAUTION REMEMBER TO USE MOTORCRAFT YN-9-A REFRIGERANT COMPRESSOR OIL WITH R-12 SYSTEMS AND MOTORCRAFT YN-12-C REFRIGERANT COMPRESSOR OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. 4. Install a new orifice tube. Refer to the Dealer Master Parts Catalog for the correct orifice tube part number. If the orifice tube in the vehicle is located in the liquid line between the condenser and the evaporator, replace the liquid line assembly. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 2985 5. Install pancake filter in the liquid line between the condenser and the orifice tube, Figure 1. a. Be sure orifice inlet is toward the condenser. b. Connections can be made using Test Adapter Set D93L-19703-B, or equivalent, and flexible refrigerant hose of 2500 psi burst rating. Individual fittings are also available. 6. Remove the old compressor following Service/Workshop Manual procedures. Drain the oil into a calibrated container. 7. Drain the oil from the replacement compressor into a clean calibrated container. NOTE: IT WILL BE NECESSARY TO TRANSFER THE MAGNET CLUTCH FROM THE OLD COMPRESSOR TO THE REPLACEMENT COMPRESSOR. FOLLOW SERVICE/WORKSHOP MANUAL PROCEDURES. 8. A new FX-15 service compressor contains 207 mL (7 oz.) of R-12 refrigerant oil. A new FS-10 service compressor does not contain any oil and can be used with an R-12 or an R-134a system. CAUTION REMEMBER TO USE YN-9-A (MINERAL) OIL WITH R-12 SYSTEMS AND YN-12-C (PAG) OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. ^ If the amount of oil drained from the removed compressor is between 90 and 148 mL (3-5 oz), pour the same amount of clean refrigerant oil into the new compressor. ^ If the amount of oil drained from the old compressor is greater than 90 mL (3 oz), pour 90 mL (3 oz) of clean refrigerant oil into the new compressor. 9. Install the new compressor following Service/Workshop Manual procedures. Make sure all mounting bolts are tightened properly. Check the tension of the compressor drive belt. Adjust if necessary. 10. Evacuate, charge and leak test the system, following Service/Workshop Manual procedures. 11. Check all refrigerant system hoses, lines and the position of the newly-installed filters to make sure they do not interfere with other engine compartment components. If necessary, use tie straps to make adjustments. 12. Set the A/C control on Max A/C, high blower and temperature control at full cold. a. Start engine and let idle briefly. b. Be sure A/C system is operating properly. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 2986 13. Gradually bring the engine up to 1200 rpm by running it at lower rpms for short periods (first at 800 rpm, then at 1000 rpm). Set the engine at 1200 rpm and run it for an hour with the A/C system operating. 14. Stop the engine. NOTE: IT WILL BE NECESSARY TO RECOVER THE SYSTEM REFRIGERANT CHARGE BEFORE PROCEEDING. 15. Allow the engine to cool sufficiently to remove the fittings, flexible hoses and pancake filter from the liquid line. 16. Discard the filter. It can be used one (1) tie only. 17. Reconnect the liquid line back into the system. 18. Evacuate, charge and leak test the system. Make any necessary adjustments. 19. Check the operation of the system in all models. PART NUMBER PART NAME F8VZ-19E773-AA Filter Kit F73Z-19577-AA Refrigerant Oil - Motorcraft YN-9-A (For R-12 Refrigerant Systems Only) F7AZ-19589-DA Refrigerant Oil - Motorcraft YN-12-C (PAG-Type Oil For R-134a Refrigerant Systems Only) NOTE THE TOTAL REPAIR TIME IS FOR INSTALLING SERVICE FILTER KIT PER INSTRUCTIONS THIS INCLUDES INSTALLATION OF AND DISCARD OF FILTER. REFER TO SERVICE LABOR TIME STANDARDS MANUALS IF ADDITIONAL LABOR OPERATIONS ARE REQUIRED. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 2987 Refrigerant: Technical Service Bulletins Air Conditioning - Use of Correct Fluorescent Tracer Dye Article No. 93-20-6 09/29/93 AIR CONDITIONING - USE OF CORRECT FLUORESCENT TRACER DYE - SERVICE TIP FORD: 1980-93 CROWN VICTORIA 1981-93 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-93 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-93 TEMPO 1986-93 TAURUS 1988-93 FESTIVA 1989-93 PROBE LINCOLN-MERCURY: 1980-93 GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1982-83 LN7, ZEPHYR 1982-86 CAPRI 1982-93 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-92 MARK VII 1984-93 TOPAZ 1986-93 SABLE 1991-93 CAPRI, TRACER LIGHT TRUCK: 1980-93 BRONCO, ECONOLINE, F-150-350 SERIES 1983-93 RANGER 1984-90 BRONCO II 1986-93 AEROSTAR 1988-93 F-47 1991-93 EXPLORER 1993 VILLAGER ISSUE: Use of untested, unapproved fluorescent tracer dyes for A/C system leak checking may damage the air conditioning system. Some of these materials may not be compatible with Ford A/C systems. ACTION: When leak-checking an R-12 A/C system with a "black light", use only Rotunda-supplied Part No. 112-R0027, Fluoro-Lite brand dye. No other dyes have been approved by Ford Motor Company. NOTE: 112-R0027 DYE IS NOT COMPATIBLE WITH R-134a REFRIGERANT. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208999 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 2988 Refrigerant: Technical Service Bulletins R-12 Refrigerant - Substitutes Article No. 94-14-3 07/13/94 Air Conditioning - Use Of R-12 Refrigerant Substitutes - Service Tip FORD: 1980-93 CROWN VICTORIA 1981-93 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-93 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-93 TEMPO 1986-93 TAURUS 1988-93 FESTIVA 1989-93 PROBE LINCOLN-MERCURY: 1980-93 GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1982-83 LN7, ZEPHYR 1982-86 CAPRI 1982-93 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-92 MARK VII 1984-93 TOPAZ 1986-93 SABLE 1991-93 CAPRI, TRACER MERKUR: 1986-89 SCORPIO, XR4TI LIGHT TRUCK: 1980-93 BRONCO, ECONOLINE, F-150-350 SERIES 1983-93 RANGER 1984-90 BRONCO II 1986-93 AEROSTAR 1988-93 F-47 1991-93 EXPLORER 1992-94 F-53 1993 VILLAGER MEDIUM/HEAVY TRUCK: 1954-90 C SERIES 1970-94 L SERIES 1979-90 CL-9000, CL-CLT-9000 SERIES 1980-94 F SERIES 1986-94 CARGO SERIES This TSB is being republished in its entirety to include Heavy Truck models. ISSUE: A number of manufacturers are producing refrigerant products which are described as being direct replacements for refrigerant R-12. The use of any unauthorized substitute refrigerant may severely damage the A/C system components. ACTION: If service is required, use only NEW or RECYCLED refrigerant R-12. Ford Motor Company has not tested or approved any R-12 refrigerant substitute at this time. R-134a is approved only for systems which specify R-134a, Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 2989 and is not compatible with R-12 systems. R-22 likewise, is not compatible with R-12 systems. CAUTION: USING ANY UNAUTHORIZED SUBSTITUTE REFRIGERANT FOR R-12 MAY RESULT IN SEVERE DAMAGE TO THE A/C SYSTEM COMPONENTS. OTHER APPLICABLE ARTICLES: 91-9-7 SUPERSEDES: 93-23-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208999, 290000 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 2990 Refrigerant: Technical Service Bulletins A/C - R12 Refrigerant Substitutes Service Tip Article No. 96-17-10 08/12/96 AIR CONDITIONING - USE OF R-12 REFRIGERANT SUBSTITUTES - SERVICE TIP FORD: 1980-93 CROWN VICTORIA 1981-93 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-93 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-94 TEMPO 1986-93 TAURUS 1988-93 FESTIVA 1989-93 PROBE LINCOLN-MERCURY: 1980-93 GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1982-83 LN7, ZEPHYR 1982-86 CAPRI 1982-93 COUGAR 1982-94 CONTINENTAL 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-93 SABLE 1991-93 CAPRI, TRACER MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1980-93 BRONCO, ECONOLINE, F SUPER DUTY, F-150-350 SERIES 1983-93 RANGER 1984-90 BRONCO II 1986-93 AEROSTAR 1988-93 F-47 1991-93 EXPLORER 1993 VILLAGER MEDIUM/HEAVY TRUCK: 1985-94 CARGO SERIES, F & B SERIES, L SERIES This TSB article is being republished in its entirety to list Environmental Protection Agency (EPA) reviewed NC substitutes for R-12 refrigerant. ISSUE: A number of manufacturers are producing refrigerant products which are described as being direct replacements for refrigerant R-12. ACTION: If service is required, use only new or of known quality recycled refrigerant R-12. Ford Motor Company has approved R-134a as the only refrigerant substitute for R-12. CAUTION: USING ANY UNAUTHORIZED SUBSTITUTE REFRIGERANT FOR R-12 MAY RESULT IN SEVERE DAMAGE TO THE A/C SYSTEM COMPONENTS. INFORMATION FROM THE EPA Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 2991 This information has been taken from EPA documents to address Ford specific applications and recommendations. Further EPA information on ozone-depleting substances and regulations regarding its handling can be found on the Internet at World Wide Web site: http://www.epa.gov/ozone/ In 1994, EPA established the Significant New Alternatives Policy (SNAP) program to review alternatives to ozone-depleting substances like R-12. EPA examines new substitutes for their ozone depleting, global warming, flammability, and toxicity characteristics. The SNAP process does not test these substitutes for A/C system compatibility, reliability, durability, or performance. Under the SNAP rule, each new refrigerant must be used in accordance with the following conditions: 1. Unique Fittings - Each new refrigerant must be used with a unique set of fittings to prevent the accidental mixing of different refrigerants. 2. Unique Equipment - Each refrigerant must have dedicated recovery/recycling equipment for that refrigerant. 3. Labels - Whether a vehicle is originally designed to use a new refrigerant or is retrofitted, the technician must apply a detailed label giving specific information about the alternative. This label covers up information about the old refrigerant and provides valuable details on the alternative and how it was used. The technician is required to fill in their name, company performing the retrofit, address and the date retrofitted. 4. Remove Original Refrigerant - The original R-12 must be removed from the system prior to charging with the new refrigerant. This will guarantee that the largest amount of clean R-12 is available for use in vehicles that still need it. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 2992 A summary of the refrigerants reviewed under EPA's SNAP program for use in motor vehicle air conditioning systems is in the table. OTHER APPLICABLE ARTICLES: 91-9-7, 96-15-7 SUPERSEDES: 93-23-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208999, 290000 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Without Rear A/C ................................................................................................................................. ....................................................................... 3.5 lbs With Rear A/C ...................................................................................................................................... ..................................................................... 4.25 lbs Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 2995 Refrigerant: Fluid Type Specifications Type ..................................................................................................................................................... ............................................... Refrigerant 12 (R-12) Ford Part Number ............................................. ........................................................................................................................................ D4AZ-19B519-A Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement Technical Service Bulletin # 98-12-5 Date: 980622 A/C - Filtering Refrigerant After Compressor Replacement Article No. 98-12-5 06/22/98 AIR CONDITIONING - FILTERING REFRIGERANT AFTER A/C COMPRESSOR REPLACEMENT - SERVICE TIPS FORD: 1980-98 CROWN VICTORIA 1981-98 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-97 THUNDERBIRD 1982-98 MUSTANG 1983-86 LTD 1984-94 TEMPO 1986-98 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-98 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1980-98 GRAND MARQUIS, TOWN CAR 1982-83 ZEPHYR 1982-86 CAPRI 1982-87 LN7 1982-97 COUGAR 1982-98 CONTINENTAL 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-98 SABLE 1991-94 CAPRI 1991-98 TRACER 1993-98 MARK VIII 1995-98-MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1980-96 BRONCO 1980-97 F SUPER DUTY 1980-98 ECONOLINE, F-150, F-150, F-350 1983-98 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F-47 1991-98 EXPLORER 1993-98 VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to revise the Service Procedure and to update the model years. ISSUE Vehicles that have and inoperative A/C compressor, due to internal causes, MUST have the refrigerant system cleaned to remove any debris or contaminants that may be present to prevent damage to the replacement compressor. ACTION Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 3000 Install a Service Filter Kit in the refrigerant system prior to installing the replacement compressor. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-15-5 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-99 Models And 1991 Lincolns, Basic Warranty Coverage For All Other Models And Major Component Warranty Coverage For All Other Lincoins OPERATION DESCRIPTION TIME 981205A Kit Installation 1.2 Hrs. 981205B Extra Time For Refrigerant 0.4 Hr. (R-12) Recovery DEALER CODING CONDITION BASIC PART NO. CODE 19703 49 OASIS CODES: 208000, 208999 Service Procedure THIS PROCEDURE IS OPTIONAL IF THE SYSTEM IS FLUSHED USING THE ROTUNDA A/C FLUSHER. CAUTION THIS FILTERING PROCEDURE MAY BE USED FOR EITHER R-12 OR R-134a REFRIGERANT SYSTEMS. BECAUSE THE TWO (2) SYSTEMS USE DIFFERENT REFRIGERANT OILS AND BECAUSE THE COMPRESSOR COULD BE DAMAGED IF THE WRONG OIL IS USED, SYSTEM IDENTIFICATION IS VERY IMPORTANT. BE SURE SYSTEM IS CORRECTLY IDENTIFIED BEFORE STARTING THE FILTERING PROCEDURE. Each Service Filter Kit includes the following items: ^ One (1) Pancake Filter (to be installed in the liquid line between the condenser and the orifice tube) ^ One (1) Instruction Sheet NOTE ON 1993-94 RANGER/EXPLORER VEHICLES, TECHNICIANS MAY EXPERIENCE DIFFICULTY WHEN CONNECTING THE PANCAKE FILTER HOSE FITTINGS TO THE EVAPORATOR INLET WITH THE ORIFICE TUBE INSTALLED. REMOVE THE OFFICE TUBE AND RUN THE SYSTEM FOR 1 HOUR AS DESCRIBED IN THE FILTERING PROCEDURE. REINSTALL THE ORIFICE TUBE AFTER FILTERING IS COMPLETE. CAUTION FOLLOW ALL REFRIGERANT SYSTEM SAFETY AND SERVICE PRECAUTIONS OUTLINED IN THE APPROPRIATE SERVICE OR WORKSHOP MANUAL. 1. Before removing any refrigerant system components, recover the refrigerant from the system following the recycling methods outlined In the appropriate Service/Workshop Manual. 2. Remove the suction accumulator/drier assembly and drain the oil into a calibrated container. 3. Install a new suction accumulator/drier and add new refrigerant oil to replace the old oil. The quantity of the new oil to be added is the amount to match that drained from the old accumulator plus 60 mL (2 oz). Refer to the Dealer Master Parts Catalog for the correct suction accumulator/drier part number. CAUTION REMEMBER TO USE MOTORCRAFT YN-9-A REFRIGERANT COMPRESSOR OIL WITH R-12 SYSTEMS AND MOTORCRAFT YN-12-C REFRIGERANT COMPRESSOR OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. 4. Install a new orifice tube. Refer to the Dealer Master Parts Catalog for the correct orifice tube part number. If the orifice tube in the vehicle is located in the liquid line between the condenser and the evaporator, replace the liquid line assembly. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 3001 5. Install pancake filter in the liquid line between the condenser and the orifice tube, Figure 1. a. Be sure orifice inlet is toward the condenser. b. Connections can be made using Test Adapter Set D93L-19703-B, or equivalent, and flexible refrigerant hose of 2500 psi burst rating. Individual fittings are also available. 6. Remove the old compressor following Service/Workshop Manual procedures. Drain the oil into a calibrated container. 7. Drain the oil from the replacement compressor into a clean calibrated container. NOTE: IT WILL BE NECESSARY TO TRANSFER THE MAGNET CLUTCH FROM THE OLD COMPRESSOR TO THE REPLACEMENT COMPRESSOR. FOLLOW SERVICE/WORKSHOP MANUAL PROCEDURES. 8. A new FX-15 service compressor contains 207 mL (7 oz.) of R-12 refrigerant oil. A new FS-10 service compressor does not contain any oil and can be used with an R-12 or an R-134a system. CAUTION REMEMBER TO USE YN-9-A (MINERAL) OIL WITH R-12 SYSTEMS AND YN-12-C (PAG) OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. ^ If the amount of oil drained from the removed compressor is between 90 and 148 mL (3-5 oz), pour the same amount of clean refrigerant oil into the new compressor. ^ If the amount of oil drained from the old compressor is greater than 90 mL (3 oz), pour 90 mL (3 oz) of clean refrigerant oil into the new compressor. 9. Install the new compressor following Service/Workshop Manual procedures. Make sure all mounting bolts are tightened properly. Check the tension of the compressor drive belt. Adjust if necessary. 10. Evacuate, charge and leak test the system, following Service/Workshop Manual procedures. 11. Check all refrigerant system hoses, lines and the position of the newly-installed filters to make sure they do not interfere with other engine compartment components. If necessary, use tie straps to make adjustments. 12. Set the A/C control on Max A/C, high blower and temperature control at full cold. a. Start engine and let idle briefly. b. Be sure A/C system is operating properly. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 3002 13. Gradually bring the engine up to 1200 rpm by running it at lower rpms for short periods (first at 800 rpm, then at 1000 rpm). Set the engine at 1200 rpm and run it for an hour with the A/C system operating. 14. Stop the engine. NOTE: IT WILL BE NECESSARY TO RECOVER THE SYSTEM REFRIGERANT CHARGE BEFORE PROCEEDING. 15. Allow the engine to cool sufficiently to remove the fittings, flexible hoses and pancake filter from the liquid line. 16. Discard the filter. It can be used one (1) tie only. 17. Reconnect the liquid line back into the system. 18. Evacuate, charge and leak test the system. Make any necessary adjustments. 19. Check the operation of the system in all models. PART NUMBER PART NAME F8VZ-19E773-AA Filter Kit F73Z-19577-AA Refrigerant Oil - Motorcraft YN-9-A (For R-12 Refrigerant Systems Only) F7AZ-19589-DA Refrigerant Oil - Motorcraft YN-12-C (PAG-Type Oil For R-134a Refrigerant Systems Only) NOTE THE TOTAL REPAIR TIME IS FOR INSTALLING SERVICE FILTER KIT PER INSTRUCTIONS THIS INCLUDES INSTALLATION OF AND DISCARD OF FILTER. REFER TO SERVICE LABOR TIME STANDARDS MANUALS IF ADDITIONAL LABOR OPERATIONS ARE REQUIRED. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications Refrigerant Oil System Capacity ......................................................................................................... ....................................................................... 10.5 oz Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 3007 Refrigerant Oil: Fluid Type Specifications Compressor ................................................................................................................... 500 viscosity (C9AZ-19557-B or Motorcraft VN-2 or equivalent) Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Auxiliary Blower Switch Blower Motor Switch: Locations Auxiliary Blower Switch RH Side Of Function Control Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations > Auxiliary Blower Switch > Page 3013 Blower Motor Switch: Locations Front Blower Switch LH Side Of Control Assembly Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature Sensor / Switch > Component Information > Locations Evaporator Temperature Sensor / Switch: Locations A/C EVAPORATOR DE-ICING SWITCH RH Dash Panel Attached To Evaporator Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Locations > Temperature Selector Vacuum Connection Block Vacuum Harness HVAC: Locations Temperature Selector Vacuum Connection Block Behind I/P Panel Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Locations > Temperature Selector Vacuum Connection Block > Page 3021 Vacuum Harness HVAC: Locations Function Control Vacuum Connection Block Behind I/P Panel Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Locations > Page 3022 Vacuum Harness HVAC: Description and Operation Engine vacuum systems a pre-assembled harness which features colored nylon vacuum lines. The color is a visual aid both in production and in service. The emission decal on the engine provides a colored schematic of the vacuum hookup which corresponds with the pre-assembled harness. Vacuum hose harnesses consist of nylon hoses a .150 inch outer diameter and a .090 inch inner diameter bonded to nylon or rubber connectors. Occasionally a rubber hose may be connected to the harness. The nylon connectors have rubber inserts to provide a seal between the nylon connector and the component connection. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Tank <--> [Vacuum Reservoir HVAC] > Component Information > Description and Operation Vacuum Tank: Description and Operation Fig. 37 Vacuum reservoirs The vacuum reservoir, Fig. 37, used on some vehicles, acts as an accumulator and prevents sudden drops or rapid fluctuations in a vacuum signal during acceleration. If vacuum in the reservoir leaks more than 1/2 inch Hg in 1 minute, the reservoir is defective and must be replaced. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Solenoid Valve HVAC > Component Information > Locations Vacuum Solenoid Valve HVAC: Locations AUXILIARY HEATER VACUUM SOLENOID VALVE Rear Of Engine RH Side Of Engine Compartment Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls: > NHTSA90V137000 > Jul > 90 > Recall 90V137000: Seat Belts/Hardware Replacement Seat Belt: Recalls Recall 90V137000: Seat Belts/Hardware Replacement OCCUPANTS WOULD NOT BE ADEQUATELY PROTECTED IN EVENT OF AN ACCIDENT OR SUDDEN STOP. INSTALL PROPER MOUNTING HARDWARE AND SEAT BELTS. NOTE: THIS RECALL WAS INITIALIZED BY MARK III INDUSTRIES. SYSTEM: SEAT BELTS, SEAT BELT ANCHORS, AND SEAT MOUNTING. DOM: SEPT. 1978 TO SEPT. 1984. DESCRIPTION ON DEFECT: IMPROPER MOUNTING HARDWARE AND IMPROPER SAFETY RESTRAINT SYSTEMS MAY HAVE BEEN INSTALLED IN THESE VEHICLES. 1978 CHEVROLET TRUCK G20 1978 DODGE TRUCK B250 1978 FORD TRUCK E150 1979 CHEVROLET TRUCK G20 1979 DODGE TRUCK B250 1979 FORD TRUCK E150 1980 CHEVROLET TRUCK G20 1980 DODGE TRUCK B250 1980 FORD TRUCK E150 1981 CHEVROLET TRUCK G20 1981 DODGE TRUCK B250 1981 FORD TRUCK E150 1982 CHEVROLET TRUCK G20 1982 DODGE TRUCK B250 1982 FORD TRUCK E150 1983 CHEVROLET TRUCK G20 1983 DODGE TRUCK B250 1983 FORD TRUCK E150 1984 CHEVROLET TRUCK G20 1984 DODGE TRUCK B250 1984 FORD TRUCK E150 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > NHTSA90V137000 > Jul > 90 > Recall 90V137000: Seat Belts/Hardware Replacement Seat Belt: All Technical Service Bulletins Recall 90V137000: Seat Belts/Hardware Replacement OCCUPANTS WOULD NOT BE ADEQUATELY PROTECTED IN EVENT OF AN ACCIDENT OR SUDDEN STOP. INSTALL PROPER MOUNTING HARDWARE AND SEAT BELTS. NOTE: THIS RECALL WAS INITIALIZED BY MARK III INDUSTRIES. SYSTEM: SEAT BELTS, SEAT BELT ANCHORS, AND SEAT MOUNTING. DOM: SEPT. 1978 TO SEPT. 1984. DESCRIPTION ON DEFECT: IMPROPER MOUNTING HARDWARE AND IMPROPER SAFETY RESTRAINT SYSTEMS MAY HAVE BEEN INSTALLED IN THESE VEHICLES. 1978 CHEVROLET TRUCK G20 1978 DODGE TRUCK B250 1978 FORD TRUCK E150 1979 CHEVROLET TRUCK G20 1979 DODGE TRUCK B250 1979 FORD TRUCK E150 1980 CHEVROLET TRUCK G20 1980 DODGE TRUCK B250 1980 FORD TRUCK E150 1981 CHEVROLET TRUCK G20 1981 DODGE TRUCK B250 1981 FORD TRUCK E150 1982 CHEVROLET TRUCK G20 1982 DODGE TRUCK B250 1982 FORD TRUCK E150 1983 CHEVROLET TRUCK G20 1983 DODGE TRUCK B250 1983 FORD TRUCK E150 1984 CHEVROLET TRUCK G20 1984 DODGE TRUCK B250 1984 FORD TRUCK E150 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 8524 > Jan > 85 > Seat/Shoulder Belts - General Service Information Technical Service Bulletin # 8524 Date: 850124 Seat/Shoulder Belts - General Service Information Article No. 85-2-4 SEAT/SHOULDER BELTS - GENERAL SERVICE INFORMATION FORD ALL - 1974-85 LINCOLN-MERCURY ALL - 1974-85 LIGHT TRUCKS ALL - 1974-85 MEDIUM/HEAVY TRUCKS ALL - 1974-85 The States of New York, New Jersey and Illinois recently enacted a mandatory seat belt usage law. With these laws and impending similar belt usage legislation in other states, dealers can expect customer inquiries regarding seat belts. The following information is being published in an effort to refamiliarize dealership service personnel with seat and shoulder belt systems utilized over the past several model years. Previous Service Recall and TSB articles pertaining to seat belt usage and servicing are also included. Section 1 -Identification of Seat Belt System Types For Model Years 1974-1985 There are three distinct types of seat belt systems. Two of the systems are three-point anchoring systems. One three-point system has dual retractors; one retractor for the lap and one for the shoulder belt. The other three-point system is the continuous loop single retractor system for the lap and shoulder belts. The third system is a two-point system that contains a lap belt only which is used for rear seat and front center passenger restraint. Continuous Loop Three-Point System The continuous loop system has a moveable tongue on the front outboard lap/shoulder belt and only one retractor. Dual Retractor Three-Point System The dual retractor system has a fixed tongue on the front outboard lap/shoulder belt. (Note that on the Econoline for 1982-85 model years, the two retractors are on one frame attached to the seat pedestal.) Front Center/Rear Seat Two-Point System A 2-point system provides a lap belt only and applies to the front seat center position and all rear seat positions. Rear outboard belts are equipped with retractors, while front and rear center belts are not. A.Continuous Loop Three-Point Shoulder/Lap Belt - System With Moveable Tongue and One Retractor - 1976 to Present Cars and Ligh Figure 5 The continuous loop three-point system (Figure 5) is used for front outboard passengers. The outboard lap/shoulder belt uses a common moveable tongue. To fasten the seat belt, the tongue is inserted into the inboard buckle. The webbing of the lap belt is anchored to the side of the body without a Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 8524 > Jan > 85 > Seat/Shoulder Belts - General Service Information > Page 3048 retractor. The shoulder harness webbing has the other end fixed in a retractor, which is located on the "B" pillar post or in the quarter panel. The shoulder harness retractor is designed to let the webbing freely move in or out, except during sufficient vehicle deceleration, when it is automatically locked by a mechanically actuated inertia sensor. The inboard (buckle) portion of the seat belt assembly passes between the seat cushion and seat back on bench seat installations, and directly to a fixed anchorage on the floor. On bucket seat installations, it is routed along the side of the seat and is fastened to a slide bar. The slide bar is connected to the seat track, the seat, and the floor pan. On LTD/Marquis and Thunderbird/Cougar, the buckle end passes between the seat and the consolette and is connected to the seat track. Attaching the tongue to the buckle secures the occupant with both lower and upper restraints. This attachment of the tongue and buckle can be accomplished by a single continuous movement. This system may also include a tension eliminator that is designed to release automatically when the respective front door is opened. As the seatbelt is unbuckled, the tongue end of the belt should be hand-guided back to the retractor to prevent the belt tongue from striking occupants or objects nearby during retraction. B.Dual Retractor Three-Point Shoulder/Lap System - 1974 to 1983 Cars and Light Trucks and 1974 to 1985 Econolines and Club Wago Figure 4 The dual retractor three-point system is used for front outboard occupants (Figure 4). The lap belt portion and shoulder harness are joined at the tongue. To secure the belt, the tongue is inserted into the buckle of the inboard belt portion. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 8524 > Jan > 85 > Seat/Shoulder Belts - General Service Information > Page 3049 Figure 4 Figure 6 Except for the 1983-85 Econoline and Club Wagon, the webbing for the outboard lap belt extends from the belt retractor located on the rocker panel that automatically locks when the belt is being worn. This locking feature prevents the belt from being pulled out further, but allows the belt to retract, thus maintaining a snug fit around the user for increased safety. This lap belt retractor is located on or in the rocker panel (depending on car line and model - Figure 4) or on the seat pedestal for 1983-85 Econoline and Club Wagon (Figure 6). Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 8524 > Jan > 85 > Seat/Shoulder Belts - General Service Information > Page 3050 Figure 4 The shoulder harness webbing has one end fixed in a retractor (Figure 4) which is located in or on the rocker panel, or in the "B" pillar post (depending on car/truck line and model). The Mustang/Capri shoulder harness retractor is located in the quarter panel. From the retractor, the webbing then passes through a guide above and behind the occupant's shoulder which directs the webbing at the proper downward angle over the occupant's shoulder and chest, and attaches the tongue to the inboard belt buckle. The shoulder harness retractor is designed to let the webbing move freely in or out at all times, except during vehicle deceleration, when the retractor is automatically locked by a mechanically actuated retractor inertia sensor. The inboard belt buckle passes through the seat cushion on a bench seat or around the side of the cushion on a bucket seat to a fixed anchorage on the floor or seat pedestal for Econolines. Attaching (locking together) the tongue and buckle secures the occupant with both lower and upper restraints. This attachment of the tongue and buckle can be accomplished by a single continuous movement. C.Two-Point System - Center Front/Rear and Rear Seat Lap Belts Those vehicles designed to accommodate a center rear seat occupant have a center lap belt without a retractor. The belt should be adjusted by the tongue to fit snugly and as low as possible around the hips. Figure 6 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 8524 > Jan > 85 > Seat/Shoulder Belts - General Service Information > Page 3051 Figure 7 In passenger cars and light trucks, the rear seat two-point lap belt system for outboard passengers has the retractor located in the quarter panel or attached to the floor under the seat (Figure 7). On Econoline, Club Wagon, Bronco and Bronco II vehicles, the rear seat retractors are attached to the seat frame or the floor. The buckle portions of the seat belt are all attached to the floor on passenger cars, and either to the floor or seat frame on Broncos and Econolines. Most rear seat lap belt retractor assemblies are equipped with a sleeve to prevent the tongue from being lost between the seat cushion and seat back. The buckle ends pass between the seat cushion and seat back. On passenger cars, the locking together of the tongue and buckle can be made by a single continuous movement. On Bronco and Econoline vehicles, the outboard buckle ends pass around the outside of the rear seat (Figure 6, View B). Section 3-Functional Test Procedure For Shoulder Harness Shoulder Harness Functional Test Procedure for Three-Point Systems (Both Dual Retractor and Continuous Loop Systems) Driver should buckle up and proceed to a test area appropriate for making sudden stops. If the RH passenger seat belt must be tested, a passenger should be buckled into the RH seat. The passenger belt may be tested utilizing a driver only, providing the driver has the ability to grasp the RH shoulder belt and extend it approximately (660 mm) 26 inches with no compromise to safe driving. This method applies to the (8 km/h) 5 mph test only. NOTE: The RH shoulder belt should not be extended during testing. This avoids the possibility of a false lock-up that is caused by a fully extended belt. After reaching an area to safely perform sudden stops, the driver should attain a speed of approximately (8 km/h) 5 mph. The driver should inform the passenger (if any), that he is preparing to make a brake application. At this time, both driver and passenger should prepare to lean slightly forward at the moment the brake application is made. The driver should make a moderately hard brake application (approximately l6 ft./sec.) without tire skid. The brake application should be on dry concrete or equivalent hard road surface (never on a wet or gravel road). The driver and passenger should lean forward slightly into the shoulder harness; at this instant, the belt retractor should lock-up without webbing payout. If there is a retractor lock-up on both driver and passenger shoulder straps, the seat belt assemblies are functioning properly. Should either or both retractors fail to lock-up at the (8 km/h) 5 mph speed, the test should be repeated at a constant (24 km/h) 15 mph. (This test must be performed with a RH passenger if the RH belt is to be tested.) If either or both shoulder belt assemblies do not lock-up at the (24 km/h) 15 mph test, the vehicle is to be returned for removal and replacement of the seat belt assembly, then retest. WARNING: WHEN REPLACING A SEAT BELT ASSEMBLY, BE SURE TO INSTALL A COMPLETE NEW ASSEMBLY (BUCKLE PORTION AND TONGUE PORTION TOGETHER) AS RECEIVED FROM FORD MOTOR COMPANY. DO NOT REPLACE ONE PART OF A SEAT BELT ASSEMBLY WITHOUT INSTALLING THE ENTIRE SEAT BELT ASSEMBLY. THIS WILL ASSURE THAT THE BUCKLE PORTION IS MANUFACTURED BY THE SAME MANUFACTURER AS THE TONGUE PORTION AND IS COMPATIBLE WITH IT. ALSO BE SURE THAT THE BELTS INSTALLED ARE INTENDED SPECIFICALLY FOR THE VEHICLE IN WHICH THEY ARE BEING INSTALLED. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 8524 > Jan > 85 > Seat/Shoulder Belts - General Service Information > Page 3052 Section 4-Functional Test Procedure For Lap Belts and Retractor Webbing Cannot Be Fully Extracted From Lap Belt Retractor - 2-Door and 4-Door (Front Outboard - Except Versailles) 1. Pull webbing from the shoulder harness retractor, allowing the lap belt to retract fully into the retractor. Pull webbing from the lap belt retractor, allow it to retract fully. 2. If OK, buckle up while sitting in seat. Repeat five times to ensure proper operation. If not OK, inspect for webbing twists in the seat belt assembly and remove the twists, if possible, without dismantling the retractor assembly. Otherwise, replace the seat belt assembly and repeat the buckle-up procedure five times. REMEMBER, A COMPLETE SEAT BELT ASSEMBLY MUST ALWAYS BE INSTALLED AS NOTED IN THE WARNING STATEMENT IN SECTIONS 3 AND 7 OF THIS ARTICLE! Lap Belt Retractor Does Not Lock - Dual Retractor 2-Door and 4-Door Models - Front Outboard Seat (Except Versailles) 1. Withdraw a minimum of 18 inches (460mm) of webbing from the lap belt retractor and check for lock-up. Retractor must lock-up after 18 inches (460mm) of webbing withdrawal and return of 2 inches (50mm) into retractor and pull out. 2. If the retractor does not lock, replace the entire seat belt assembly and retest. REMEMBER, A COMPLETE SEAT BELT ASSEMBLY MUST ALWAYS BE INSTALLED AS NOTED IN THE WARNING STATEMENT IN SECTIONS 3 AND 7 OF THIS ARTICLE! Lap Belt Retractor Does Not Lock - Dual Retractor 2-Door and 4-Door Models - Front Outboard Seat (Versailles Only) 1. Fasten the seat belt. Pull on the lap belt webbing - the retractor should be locked if OK. Unbuckle, allow the lap belt retractor to fully retract. 2. Repeat Step 1 five (5) times to ensure proper operation. 3. If not OK, replace the seat belt assembly for that seating position and retest. REMEMBER, A COMPLETE SEAT BELT ASSEMBLY MUST ALWAYS BE INSTALLED AS NOTED IN THE WARNING STATEMENT IN SECTIONS 3 AND 7 OF THIS ARTICLE! NOTE: There are two ways to stop the retractor from "free wheeling". One way is to "buckle up" and the retractor will lock immediately. The second way is to pull approximately 12" of webbing from the lap belt retractor, wait approximately 15 seconds, and a thermal timer will deactivate the "free wheeling" feature. Webbing Cannot Be Fully Extracted From Lap Belt Retractor 1. If the webbing cannot be pulled from the lap belt retractor, it may be twisted and jammed in a partially extended position. If the twist can be removed without retractor disassembly, allow the webbing to fully retract and then withdraw a minimum of 18 inches (460mm) of webbing from the retractor, return 2 inches (50mm) and check for lock-up. If OK, allow to retract fully and buckle up while sitting in the seat. Repeat five times to ensure proper operation. Verify that belt webbing can be extended far enough to expose the manufacturer's certification label. 2. If not OK, replace the seat belt assembly and repeat appropriate portions of Step 1, above. REMEMBER, A COMPLETE SEAT BELT ASSEMBLY MUST ALWAYS BE INSTALLED AS NOTED IN THE WARNING STATEMENT IN SECTIONS 3 AND 7 OF THIS ARTICLE! Figure 7 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 8524 > Jan > 85 > Seat/Shoulder Belts - General Service Information > Page 3053 Seats - Rear - Lap Belt Retractor Does Not Lock - 2-Point System (Figure 7) 1. Withdraw a minimum of 18 inches (460mm) of webbing from lap belt retractor and check for lock-up. Retractor must lock-up after 18 inches (460mm) of webbing withdrawn and return of 2 inches (50mm) into retractor and pull out. If OK, allow it to retract fully and buckle up while sitting in the seat. Repeat five times to ensure proper operation. 2. If not OK, replace seat belt assembly and repeat Step 1. REMEMBER, A COMPLETE SEAT BELT ASSEMBLY MUST ALWAYS BE INSTALLED AS NOTED IN THE WARNING STATEMENT IN SECTIONS 3 AND 7 OF THIS ARTICLE! 3. If the retractor of a new seat belt assembly has been bolted into a damaged or distorted mounting area, the new retractor could be warped and may not function. If this is the case, service the sheet metal in the area of the retractor mounting and install a new belt assembly. REMEMBER, A COMPLETE SEAT BELT ASSEMBLY MUST ALWAYS BE INSTALLED AS NOTED IN THE WARNING STATEMENT IN SECTIONS 3 AND 7 OF THIS ARTICLE! Buckle Does Not Latch - All Belts If the tongue will not latch into the buckle securely, a coin or other foreign object may be interfering with proper buckle operation. Remove the object, if possible, and recheck for secure latching. If not OK, replace the belt assembly. REMEMBER, A COMPLETE SEAT BELT ASSEMBLY MUST ALWAYS BE INSTALLED AS NOTED IN THE WARNING STATEMENT IN SECTIONS 3 AND 7 OF THIS ARTICLE! Section 5-Seat Belt Procedure After an Accident NOTE: ALL SEAT BELT ASSEMBLIES INCLUDING RETRACTORS AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. FORD RECOMMENDS THAT ALL SEAT BELT ASSEMBLIES IN USE DURING A COLLISION BE REPLACED UNLESS THE COLLISION WAS MINOR AND THE BELTS SHOW NO DAMAGE AND CONTINUE TO OPERATE PROPERLY. SEAT BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. Before installing the new seat belt assembly, the seat belt attaching areas must be inspected for damage and distortion, and if the attaching points are damaged or distorted, the sheet metal must be reworked back to its original shape and structural integrity. Install the new seat belt assembly in matched sets using the appropriate instructions; then functionally test as described previously in this article. Section 6-Cleaning Belt Webbing Clean the belt webbing with any mild soap solution recommended for cleaning upholstery or carpets; follow instructions provided with the soap. Do not bleach or re-dye the webbing because it may weaken the belt webbing. Section 7-Service Parts The Ford Motor Company stocks replacement parts for all passenger car safety belt systems for which there is nominal demand without regard to the age of vehicle. Beyond this, in the interest of ensuring that the full protection of safety belts is available for all Ford owners, the Company will undertake to provide parts to service the belt system for any Company vehicle if it was originally equipped with safety belts. Seat belt and shoulder assembly part numbers for specific applications can be identified by referring to Body Section 611 of the parts catalog. In general, these assemblies are available with black webbing only once the vehicle is beyond two years out of production. Part orders should be placed through the normal PDC system. WARNING: WHEN REPLACING A SEAT BELT ASSEMBLY, BE SURE TO INSTALL A COMPLETE NEW ASSEMBLY (BUCKLE PORTION AND TONGUE PORTION TOGETHER) AS RECEIVED FROM FORD MOTOR COMPANY. DO NOT REPLACE ONE PART OF A SEAT BELT ASSEMBLY WITHOUT INSTALLING THE ENTIRE SEAT BELT ASSEMBLY. THIS WILL ASSURE THAT THE BUCKLE PORTION IS MANUFACTURED BY THE SAME MANUFACTURER AS THE TONGUE PORTION AND IS COMPATIBLE WITH IT. ALSO BE SURE THAT THE BELTS INSTALLED ARE INTENDED SPECIFICALLY FOR THE VEHICLE IN WHICH THEY ARE BEING INSTALLED. QUICK REFERENCE PARTS LISTING FOR SEAT BELTS, COMFORT CLIPS, AND EXTENDERS Extenders offer eight inches of additional length and can be used in all seating positions. It is necessary to ensure that the manufacturer of the extender being installed is the same as that identified on the seat belt assembly. Part numbers for comfort clips used in the 3-point system, seat belts, extenders are shown below. Quick Reference Part Listing Book Microfiche Section Page Plate Row Column Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 8524 > Jan > 85 > Seat/Shoulder Belts - General Service Information > Page 3054 Car Seat Belt Extenders 1973-1979 611 2 F4 10 01 and Seat Belts 1973-1979 611 2 M4 9 56 1980- 611 1 F3 23 47 1980- 611 1 M3 23 47 Truck Seat Belt Extenders 1973-1979 600 3 LT2 20 48 and Seat Belts 1980- 600 4 LT2 11 04 All Vehicles Comfort Clips 1973-1979 600 8 F4 9 63 Section 8-Service Recalls Involving Seat Belts Recall # Letter Dated Year Car Line Concern H1B 11/17/1971 1972 Pinto, T-Bird, Light Truck Seat belt or shoulder belt bolt fracture C-2H 7/10/1972 1972 Mark IV Belt retractor won't lock up H-2H 7/10/1972 1972 Thunderbird Belt retractor won't lock up C-3E 7/31/1972 1972 Montego Belt retractor won't lock up H-3E 7/31/1972 1972 Torino Belt retractor won't lock up H-3F 7/31/1972 71-72 F-Series Lt. & Med. Incorrect length shoulder belt - no adjustment H-9D 6/1973 1973 Ford, Pinto, Lt. Truck Seat belt bolt fracture 118 3/20/1974 1974 Torino Retractor remains unlocked 130 8/26/1974 1975 Mercury Mixed part assys. - no seat belt latching 152 2/14/1975 1972 Maverick, Comet Need longer belts 189 4/26/1976 1976 W-Series Belt too short 214 12/4/1976 76-77 Granada, Monarch Shoulder belt weld nut replacement 253 2/22/1978 72-78 L8OO/900, L8000/9000 Belt too short 282 3/30/1978 1978 Pinto, Bobcat, Mustang II Retractor won't lock up 289 8/29/1978 1978 T-Bird, Cougar, LTD II, Ford Retractor won't lock up 298 9/20/1978 1978 F-Series Weld nut replacement 313 10/25/1978 1979 Econolines Possible cut belt by the seat 1536 11/1/1978 1979 Versailles Retractor solenoid drawing constant current, discharging battery 458 3/30/1983 81-82 Escort, Lynx Wagon Shoulder belt anchorage reinforcement 477 12/12/1983 1984 Escort/Lynx (3 dr.), Tempo/ D-ring bolt replacement Topaz (2 dr.), Mustang/Capri, T-Bird/Cougar, LTD/Marquis, Mark VII, Continental, Ford/ Mercury, Lincoln, Ranger, Bronco II, Bronco 477-S 2/23/1984 1984 Bronco, Bronco II, Ranger D-ring covers 489 8/8/1984 81-84 Escort/Lynx, Tempo/Topaz Belt protective spacers Section 9-TSB's Involving Seat Belts TSB # Title Other Information 198 Unauthorized Service Replace belt assembly 81-2-6 Securing Tot Guard Seat belt extender 81-5-3 Seat Belt Discoloration (Red) Truck, Escort/Lynx 1981 81-7-23 Seat Belt Becomes Tight While Driving Seat belt replacement 83-18-15 Seat Belt Rattles Against Trim Seat belt replacement 84-4-4 D-Ring Bind - Restricts Extraction of Belt Addition of spacer 84-11-1 D-Ring Cover Bind - Belt Free Swing D-ring cover replacement 41-50-8 See following page OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 8524 > Jan > 85 > Seat/Shoulder Belts - General Service Information Technical Service Bulletin # 8524 Date: 850124 Seat/Shoulder Belts - General Service Information Article No. 85-2-4 SEAT/SHOULDER BELTS - GENERAL SERVICE INFORMATION FORD ALL - 1974-85 LINCOLN-MERCURY ALL - 1974-85 LIGHT TRUCKS ALL - 1974-85 MEDIUM/HEAVY TRUCKS ALL - 1974-85 The States of New York, New Jersey and Illinois recently enacted a mandatory seat belt usage law. With these laws and impending similar belt usage legislation in other states, dealers can expect customer inquiries regarding seat belts. The following information is being published in an effort to refamiliarize dealership service personnel with seat and shoulder belt systems utilized over the past several model years. Previous Service Recall and TSB articles pertaining to seat belt usage and servicing are also included. Section 1 -Identification of Seat Belt System Types For Model Years 1974-1985 There are three distinct types of seat belt systems. Two of the systems are three-point anchoring systems. One three-point system has dual retractors; one retractor for the lap and one for the shoulder belt. The other three-point system is the continuous loop single retractor system for the lap and shoulder belts. The third system is a two-point system that contains a lap belt only which is used for rear seat and front center passenger restraint. Continuous Loop Three-Point System The continuous loop system has a moveable tongue on the front outboard lap/shoulder belt and only one retractor. Dual Retractor Three-Point System The dual retractor system has a fixed tongue on the front outboard lap/shoulder belt. (Note that on the Econoline for 1982-85 model years, the two retractors are on one frame attached to the seat pedestal.) Front Center/Rear Seat Two-Point System A 2-point system provides a lap belt only and applies to the front seat center position and all rear seat positions. Rear outboard belts are equipped with retractors, while front and rear center belts are not. A.Continuous Loop Three-Point Shoulder/Lap Belt - System With Moveable Tongue and One Retractor - 1976 to Present Cars and Ligh Figure 5 The continuous loop three-point system (Figure 5) is used for front outboard passengers. The outboard lap/shoulder belt uses a common moveable tongue. To fasten the seat belt, the tongue is inserted into the inboard buckle. The webbing of the lap belt is anchored to the side of the body without a Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 8524 > Jan > 85 > Seat/Shoulder Belts - General Service Information > Page 3060 retractor. The shoulder harness webbing has the other end fixed in a retractor, which is located on the "B" pillar post or in the quarter panel. The shoulder harness retractor is designed to let the webbing freely move in or out, except during sufficient vehicle deceleration, when it is automatically locked by a mechanically actuated inertia sensor. The inboard (buckle) portion of the seat belt assembly passes between the seat cushion and seat back on bench seat installations, and directly to a fixed anchorage on the floor. On bucket seat installations, it is routed along the side of the seat and is fastened to a slide bar. The slide bar is connected to the seat track, the seat, and the floor pan. On LTD/Marquis and Thunderbird/Cougar, the buckle end passes between the seat and the consolette and is connected to the seat track. Attaching the tongue to the buckle secures the occupant with both lower and upper restraints. This attachment of the tongue and buckle can be accomplished by a single continuous movement. This system may also include a tension eliminator that is designed to release automatically when the respective front door is opened. As the seatbelt is unbuckled, the tongue end of the belt should be hand-guided back to the retractor to prevent the belt tongue from striking occupants or objects nearby during retraction. B.Dual Retractor Three-Point Shoulder/Lap System - 1974 to 1983 Cars and Light Trucks and 1974 to 1985 Econolines and Club Wago Figure 4 The dual retractor three-point system is used for front outboard occupants (Figure 4). The lap belt portion and shoulder harness are joined at the tongue. To secure the belt, the tongue is inserted into the buckle of the inboard belt portion. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 8524 > Jan > 85 > Seat/Shoulder Belts - General Service Information > Page 3061 Figure 4 Figure 6 Except for the 1983-85 Econoline and Club Wagon, the webbing for the outboard lap belt extends from the belt retractor located on the rocker panel that automatically locks when the belt is being worn. This locking feature prevents the belt from being pulled out further, but allows the belt to retract, thus maintaining a snug fit around the user for increased safety. This lap belt retractor is located on or in the rocker panel (depending on car line and model - Figure 4) or on the seat pedestal for 1983-85 Econoline and Club Wagon (Figure 6). Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 8524 > Jan > 85 > Seat/Shoulder Belts - General Service Information > Page 3062 Figure 4 The shoulder harness webbing has one end fixed in a retractor (Figure 4) which is located in or on the rocker panel, or in the "B" pillar post (depending on car/truck line and model). The Mustang/Capri shoulder harness retractor is located in the quarter panel. From the retractor, the webbing then passes through a guide above and behind the occupant's shoulder which directs the webbing at the proper downward angle over the occupant's shoulder and chest, and attaches the tongue to the inboard belt buckle. The shoulder harness retractor is designed to let the webbing move freely in or out at all times, except during vehicle deceleration, when the retractor is automatically locked by a mechanically actuated retractor inertia sensor. The inboard belt buckle passes through the seat cushion on a bench seat or around the side of the cushion on a bucket seat to a fixed anchorage on the floor or seat pedestal for Econolines. Attaching (locking together) the tongue and buckle secures the occupant with both lower and upper restraints. This attachment of the tongue and buckle can be accomplished by a single continuous movement. C.Two-Point System - Center Front/Rear and Rear Seat Lap Belts Those vehicles designed to accommodate a center rear seat occupant have a center lap belt without a retractor. The belt should be adjusted by the tongue to fit snugly and as low as possible around the hips. Figure 6 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 8524 > Jan > 85 > Seat/Shoulder Belts - General Service Information > Page 3063 Figure 7 In passenger cars and light trucks, the rear seat two-point lap belt system for outboard passengers has the retractor located in the quarter panel or attached to the floor under the seat (Figure 7). On Econoline, Club Wagon, Bronco and Bronco II vehicles, the rear seat retractors are attached to the seat frame or the floor. The buckle portions of the seat belt are all attached to the floor on passenger cars, and either to the floor or seat frame on Broncos and Econolines. Most rear seat lap belt retractor assemblies are equipped with a sleeve to prevent the tongue from being lost between the seat cushion and seat back. The buckle ends pass between the seat cushion and seat back. On passenger cars, the locking together of the tongue and buckle can be made by a single continuous movement. On Bronco and Econoline vehicles, the outboard buckle ends pass around the outside of the rear seat (Figure 6, View B). Section 3-Functional Test Procedure For Shoulder Harness Shoulder Harness Functional Test Procedure for Three-Point Systems (Both Dual Retractor and Continuous Loop Systems) Driver should buckle up and proceed to a test area appropriate for making sudden stops. If the RH passenger seat belt must be tested, a passenger should be buckled into the RH seat. The passenger belt may be tested utilizing a driver only, providing the driver has the ability to grasp the RH shoulder belt and extend it approximately (660 mm) 26 inches with no compromise to safe driving. This method applies to the (8 km/h) 5 mph test only. NOTE: The RH shoulder belt should not be extended during testing. This avoids the possibility of a false lock-up that is caused by a fully extended belt. After reaching an area to safely perform sudden stops, the driver should attain a speed of approximately (8 km/h) 5 mph. The driver should inform the passenger (if any), that he is preparing to make a brake application. At this time, both driver and passenger should prepare to lean slightly forward at the moment the brake application is made. The driver should make a moderately hard brake application (approximately l6 ft./sec.) without tire skid. The brake application should be on dry concrete or equivalent hard road surface (never on a wet or gravel road). The driver and passenger should lean forward slightly into the shoulder harness; at this instant, the belt retractor should lock-up without webbing payout. If there is a retractor lock-up on both driver and passenger shoulder straps, the seat belt assemblies are functioning properly. Should either or both retractors fail to lock-up at the (8 km/h) 5 mph speed, the test should be repeated at a constant (24 km/h) 15 mph. (This test must be performed with a RH passenger if the RH belt is to be tested.) If either or both shoulder belt assemblies do not lock-up at the (24 km/h) 15 mph test, the vehicle is to be returned for removal and replacement of the seat belt assembly, then retest. WARNING: WHEN REPLACING A SEAT BELT ASSEMBLY, BE SURE TO INSTALL A COMPLETE NEW ASSEMBLY (BUCKLE PORTION AND TONGUE PORTION TOGETHER) AS RECEIVED FROM FORD MOTOR COMPANY. DO NOT REPLACE ONE PART OF A SEAT BELT ASSEMBLY WITHOUT INSTALLING THE ENTIRE SEAT BELT ASSEMBLY. THIS WILL ASSURE THAT THE BUCKLE PORTION IS MANUFACTURED BY THE SAME MANUFACTURER AS THE TONGUE PORTION AND IS COMPATIBLE WITH IT. ALSO BE SURE THAT THE BELTS INSTALLED ARE INTENDED SPECIFICALLY FOR THE VEHICLE IN WHICH THEY ARE BEING INSTALLED. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 8524 > Jan > 85 > Seat/Shoulder Belts - General Service Information > Page 3064 Section 4-Functional Test Procedure For Lap Belts and Retractor Webbing Cannot Be Fully Extracted From Lap Belt Retractor - 2-Door and 4-Door (Front Outboard - Except Versailles) 1. Pull webbing from the shoulder harness retractor, allowing the lap belt to retract fully into the retractor. Pull webbing from the lap belt retractor, allow it to retract fully. 2. If OK, buckle up while sitting in seat. Repeat five times to ensure proper operation. If not OK, inspect for webbing twists in the seat belt assembly and remove the twists, if possible, without dismantling the retractor assembly. Otherwise, replace the seat belt assembly and repeat the buckle-up procedure five times. REMEMBER, A COMPLETE SEAT BELT ASSEMBLY MUST ALWAYS BE INSTALLED AS NOTED IN THE WARNING STATEMENT IN SECTIONS 3 AND 7 OF THIS ARTICLE! Lap Belt Retractor Does Not Lock - Dual Retractor 2-Door and 4-Door Models - Front Outboard Seat (Except Versailles) 1. Withdraw a minimum of 18 inches (460mm) of webbing from the lap belt retractor and check for lock-up. Retractor must lock-up after 18 inches (460mm) of webbing withdrawal and return of 2 inches (50mm) into retractor and pull out. 2. If the retractor does not lock, replace the entire seat belt assembly and retest. REMEMBER, A COMPLETE SEAT BELT ASSEMBLY MUST ALWAYS BE INSTALLED AS NOTED IN THE WARNING STATEMENT IN SECTIONS 3 AND 7 OF THIS ARTICLE! Lap Belt Retractor Does Not Lock - Dual Retractor 2-Door and 4-Door Models - Front Outboard Seat (Versailles Only) 1. Fasten the seat belt. Pull on the lap belt webbing - the retractor should be locked if OK. Unbuckle, allow the lap belt retractor to fully retract. 2. Repeat Step 1 five (5) times to ensure proper operation. 3. If not OK, replace the seat belt assembly for that seating position and retest. REMEMBER, A COMPLETE SEAT BELT ASSEMBLY MUST ALWAYS BE INSTALLED AS NOTED IN THE WARNING STATEMENT IN SECTIONS 3 AND 7 OF THIS ARTICLE! NOTE: There are two ways to stop the retractor from "free wheeling". One way is to "buckle up" and the retractor will lock immediately. The second way is to pull approximately 12" of webbing from the lap belt retractor, wait approximately 15 seconds, and a thermal timer will deactivate the "free wheeling" feature. Webbing Cannot Be Fully Extracted From Lap Belt Retractor 1. If the webbing cannot be pulled from the lap belt retractor, it may be twisted and jammed in a partially extended position. If the twist can be removed without retractor disassembly, allow the webbing to fully retract and then withdraw a minimum of 18 inches (460mm) of webbing from the retractor, return 2 inches (50mm) and check for lock-up. If OK, allow to retract fully and buckle up while sitting in the seat. Repeat five times to ensure proper operation. Verify that belt webbing can be extended far enough to expose the manufacturer's certification label. 2. If not OK, replace the seat belt assembly and repeat appropriate portions of Step 1, above. REMEMBER, A COMPLETE SEAT BELT ASSEMBLY MUST ALWAYS BE INSTALLED AS NOTED IN THE WARNING STATEMENT IN SECTIONS 3 AND 7 OF THIS ARTICLE! Figure 7 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 8524 > Jan > 85 > Seat/Shoulder Belts - General Service Information > Page 3065 Seats - Rear - Lap Belt Retractor Does Not Lock - 2-Point System (Figure 7) 1. Withdraw a minimum of 18 inches (460mm) of webbing from lap belt retractor and check for lock-up. Retractor must lock-up after 18 inches (460mm) of webbing withdrawn and return of 2 inches (50mm) into retractor and pull out. If OK, allow it to retract fully and buckle up while sitting in the seat. Repeat five times to ensure proper operation. 2. If not OK, replace seat belt assembly and repeat Step 1. REMEMBER, A COMPLETE SEAT BELT ASSEMBLY MUST ALWAYS BE INSTALLED AS NOTED IN THE WARNING STATEMENT IN SECTIONS 3 AND 7 OF THIS ARTICLE! 3. If the retractor of a new seat belt assembly has been bolted into a damaged or distorted mounting area, the new retractor could be warped and may not function. If this is the case, service the sheet metal in the area of the retractor mounting and install a new belt assembly. REMEMBER, A COMPLETE SEAT BELT ASSEMBLY MUST ALWAYS BE INSTALLED AS NOTED IN THE WARNING STATEMENT IN SECTIONS 3 AND 7 OF THIS ARTICLE! Buckle Does Not Latch - All Belts If the tongue will not latch into the buckle securely, a coin or other foreign object may be interfering with proper buckle operation. Remove the object, if possible, and recheck for secure latching. If not OK, replace the belt assembly. REMEMBER, A COMPLETE SEAT BELT ASSEMBLY MUST ALWAYS BE INSTALLED AS NOTED IN THE WARNING STATEMENT IN SECTIONS 3 AND 7 OF THIS ARTICLE! Section 5-Seat Belt Procedure After an Accident NOTE: ALL SEAT BELT ASSEMBLIES INCLUDING RETRACTORS AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. FORD RECOMMENDS THAT ALL SEAT BELT ASSEMBLIES IN USE DURING A COLLISION BE REPLACED UNLESS THE COLLISION WAS MINOR AND THE BELTS SHOW NO DAMAGE AND CONTINUE TO OPERATE PROPERLY. SEAT BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. Before installing the new seat belt assembly, the seat belt attaching areas must be inspected for damage and distortion, and if the attaching points are damaged or distorted, the sheet metal must be reworked back to its original shape and structural integrity. Install the new seat belt assembly in matched sets using the appropriate instructions; then functionally test as described previously in this article. Section 6-Cleaning Belt Webbing Clean the belt webbing with any mild soap solution recommended for cleaning upholstery or carpets; follow instructions provided with the soap. Do not bleach or re-dye the webbing because it may weaken the belt webbing. Section 7-Service Parts The Ford Motor Company stocks replacement parts for all passenger car safety belt systems for which there is nominal demand without regard to the age of vehicle. Beyond this, in the interest of ensuring that the full protection of safety belts is available for all Ford owners, the Company will undertake to provide parts to service the belt system for any Company vehicle if it was originally equipped with safety belts. Seat belt and shoulder assembly part numbers for specific applications can be identified by referring to Body Section 611 of the parts catalog. In general, these assemblies are available with black webbing only once the vehicle is beyond two years out of production. Part orders should be placed through the normal PDC system. WARNING: WHEN REPLACING A SEAT BELT ASSEMBLY, BE SURE TO INSTALL A COMPLETE NEW ASSEMBLY (BUCKLE PORTION AND TONGUE PORTION TOGETHER) AS RECEIVED FROM FORD MOTOR COMPANY. DO NOT REPLACE ONE PART OF A SEAT BELT ASSEMBLY WITHOUT INSTALLING THE ENTIRE SEAT BELT ASSEMBLY. THIS WILL ASSURE THAT THE BUCKLE PORTION IS MANUFACTURED BY THE SAME MANUFACTURER AS THE TONGUE PORTION AND IS COMPATIBLE WITH IT. ALSO BE SURE THAT THE BELTS INSTALLED ARE INTENDED SPECIFICALLY FOR THE VEHICLE IN WHICH THEY ARE BEING INSTALLED. QUICK REFERENCE PARTS LISTING FOR SEAT BELTS, COMFORT CLIPS, AND EXTENDERS Extenders offer eight inches of additional length and can be used in all seating positions. It is necessary to ensure that the manufacturer of the extender being installed is the same as that identified on the seat belt assembly. Part numbers for comfort clips used in the 3-point system, seat belts, extenders are shown below. Quick Reference Part Listing Book Microfiche Section Page Plate Row Column Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt: > 8524 > Jan > 85 > Seat/Shoulder Belts - General Service Information > Page 3066 Car Seat Belt Extenders 1973-1979 611 2 F4 10 01 and Seat Belts 1973-1979 611 2 M4 9 56 1980- 611 1 F3 23 47 1980- 611 1 M3 23 47 Truck Seat Belt Extenders 1973-1979 600 3 LT2 20 48 and Seat Belts 1980- 600 4 LT2 11 04 All Vehicles Comfort Clips 1973-1979 600 8 F4 9 63 Section 8-Service Recalls Involving Seat Belts Recall # Letter Dated Year Car Line Concern H1B 11/17/1971 1972 Pinto, T-Bird, Light Truck Seat belt or shoulder belt bolt fracture C-2H 7/10/1972 1972 Mark IV Belt retractor won't lock up H-2H 7/10/1972 1972 Thunderbird Belt retractor won't lock up C-3E 7/31/1972 1972 Montego Belt retractor won't lock up H-3E 7/31/1972 1972 Torino Belt retractor won't lock up H-3F 7/31/1972 71-72 F-Series Lt. & Med. Incorrect length shoulder belt - no adjustment H-9D 6/1973 1973 Ford, Pinto, Lt. Truck Seat belt bolt fracture 118 3/20/1974 1974 Torino Retractor remains unlocked 130 8/26/1974 1975 Mercury Mixed part assys. - no seat belt latching 152 2/14/1975 1972 Maverick, Comet Need longer belts 189 4/26/1976 1976 W-Series Belt too short 214 12/4/1976 76-77 Granada, Monarch Shoulder belt weld nut replacement 253 2/22/1978 72-78 L8OO/900, L8000/9000 Belt too short 282 3/30/1978 1978 Pinto, Bobcat, Mustang II Retractor won't lock up 289 8/29/1978 1978 T-Bird, Cougar, LTD II, Ford Retractor won't lock up 298 9/20/1978 1978 F-Series Weld nut replacement 313 10/25/1978 1979 Econolines Possible cut belt by the seat 1536 11/1/1978 1979 Versailles Retractor solenoid drawing constant current, discharging battery 458 3/30/1983 81-82 Escort, Lynx Wagon Shoulder belt anchorage reinforcement 477 12/12/1983 1984 Escort/Lynx (3 dr.), Tempo/ D-ring bolt replacement Topaz (2 dr.), Mustang/Capri, T-Bird/Cougar, LTD/Marquis, Mark VII, Continental, Ford/ Mercury, Lincoln, Ranger, Bronco II, Bronco 477-S 2/23/1984 1984 Bronco, Bronco II, Ranger D-ring covers 489 8/8/1984 81-84 Escort/Lynx, Tempo/Topaz Belt protective spacers Section 9-TSB's Involving Seat Belts TSB # Title Other Information 198 Unauthorized Service Replace belt assembly 81-2-6 Securing Tot Guard Seat belt extender 81-5-3 Seat Belt Discoloration (Red) Truck, Escort/Lynx 1981 81-7-23 Seat Belt Becomes Tight While Driving Seat belt replacement 83-18-15 Seat Belt Rattles Against Trim Seat belt replacement 84-4-4 D-Ring Bind - Restricts Extraction of Belt Addition of spacer 84-11-1 D-Ring Cover Bind - Belt Free Swing D-ring cover replacement 41-50-8 See following page OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Switch: Locations Part Of Driver's Seat Belt Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Latch > Component Information > Technical Service Bulletins > Safety Belt - Tongue Cover Now Available Seat Belt Latch: Technical Service Bulletins Safety Belt - Tongue Cover Now Available SAFETY BELT - TONGUE COVER SERVICE PART AVAILABILITY Article No. 88-25-2 FORD: 1974-88 ALL LINCOLN-MERCURY: 1974-88 ALL LIGHT-TRUCK: 1974-88 ALL MEDIUM/HEAVY: 1974-88 ISSUE: The safety belt tongue cover is now available for service. It is no longer necessary to replace the entire safety belt assembly in the event a buckle and tongue cover requires service. ACTION: No corrective action is required. Refer to the following application chart for the correct service part number. NOTE: THE SAFETY BELT TONGUE COVERS ARE SERVICED IN A NEUTRAL COLOR AND MUST BE PAINTED TO MATCH. SAFETY BELT TONGUE COVER APPLICATION CHART MODEL YEAR VEHICLE SERVICE PART NO. 1986-88 Taurus/Sable E7DZ-54612A64-A 1974-88 All Other Vehicles E7FZ-61612A64-A PART NUMBER PART NAME CLASS E7DZ-54612A64-A Safety Belt Tongue Cover Package of 4 BM E7FZ-61612A64-A Safety Belt Tongue Cover Package of 4 B OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 1050, 1051, 1800 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Seat Belt Buckle Switch: Locations Part Of Driver's Seat Belt Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > System Information > Technical Service Bulletins > Antitheft Devices - Installation Precautions Antitheft and Alarm Systems: Technical Service Bulletins Antitheft Devices - Installation Precautions Article No. 86-3-9 ANTI-THEFT DEVICES (AFTER MARKET) - INSTALLATION/ OPERATING PRECAUTIONS ON VEHICLES EQUIPPED WITH ELECTRONIC ENGINE CONTROLS (EEC) FORD 1978-86 ALL LINCOLN-MERCURY 1978-86 ALL LIGHT TRUCK 1981-86 ALL NOTE: This article is being republished in its entirety to include 1986 models. Installation of "AfterMarket" anti-theft devices such as fuel shutoff and ignition defeating devices may cause no starts, hard starting, stalls, or damage to vehicle components on Ford vehicles equipped with electronic engine controls. Possible damage caused by these devices can result from the following situations: 1. Fuel shutoff devices - Attempting to start the vehicle without disarming this device may cause the fuel injectors to run dry and overheat, which will lead to failure of the injectors. 2. Ignition defeating devices which ground the ignition/tachometer lead - Attempting to start the vehicle without disarming may result in ignition coil failure. Figure 13 In addition, care must be taken when routing underhood after market wiring (see Figure 13 for proper precautions), in order to avoid electromagnetic interference with electronic engine controls. The following precautions must be observed: Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > System Information > Technical Service Bulletins > Antitheft Devices - Installation Precautions > Page 3083 1. Ignition tach signal wiring must not be randomly routed through the engine compartment. 2. Add-on wiring must not run parallel to secondary (plug) ignition wires. 3. EEC wiring harness (12A581) must not be altered or cut or rerouted. Failure to observe these warnings may result in damage to vehicle components or drive deterioration. OTHER APPLICABLE ARTICLES: Supersedes 85-7-8 WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio Power Boost Switch > Component Information > Locations Radio Power Boost Switch: Locations Attached To RH Cowl Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Locations Radio/Stereo Noise Filter: Locations Below Voltage Regulator Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Radio Power Boost Switch > Component Information > Locations Radio Power Boost Switch: Locations Attached To RH Cowl Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lighting Relay > Component Information > Locations Trailer Lighting Relay: Locations LH Rear Fender Below LH Taillight Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Lower Side Moulding / Trim > Component Information > Technical Service Bulletins > Body - Spot Weld Marks On Side Panels Lower Side Moulding / Trim: Technical Service Bulletins Body - Spot Weld Marks On Side Panels Article No. 85-6-15 SHEET METAL - SPOT WELD MARKS ON BODY SIDE PANELS LIGHT TRUCK 1980-85 ECONOLINE Spot weld marks along the lower body side panels at the character line of Econoline vehicles may affect appearance or customer satisfaction. This condition can be resolved with the installation of a 24mm wide adhesively attached body side molding kit now available as a service kit. The moldings are applied along the character line from the rear of the front fender to the rear of the vehicle. This service only kit is pre-cut, and requires only cleaning the surface of all wax and dirt, peeling the plastic backing from the molding and applying the molding in the designated area. The body side molding kit is designed to fit both the 124 inch and 138 inch wheelbase units with either sliding or cargo side doors. PART NUMBER PART NAME CLASS E5UZ-2221048-A Body Side Molding Kit BA OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > Suspension - #1 Crossmember Service Replacement Cross-Member: Technical Service Bulletins Suspension - #1 Crossmember Service Replacement Artile No. 83-18-18 FRAME - #1 CROSSMEMBER - SERVICE REPLACEMENT LIGHT TRUCKS 1980-83 F100-350, BRONCO; 1975-83 ECONOLINE Number 1 crossmember kits are now available for usage where damaged crossmembers require complete replacement. The kits will service all vehicles except HD F-250/350 with 6.9L or 7.5L engines. The kits include detailed installation instructions and necessary fasteners to assure a durable replacement. In instances where the crossmember has minimal damage confined to areas surrounding the pivot brackets, complete replacement may not be required. In these cases, your District Zone Service Manager should be contacted regarding the potential usage of a reinforcing kit instead of complete replacement of the crossmember. PART NUMBER PART NAME CLASS D5UZ-5C139-A Kit - #1 Crossmember C Econoline E0TZ-5C139-A Kit - #1 Crossmember C Bronco, F100-350 (Coil Springs) (except 6.9L, 7.5L engines) E0TZ-5C139-B Kit - #1 Crossmember C F-250/350 (4x4) (leaf springs) (except 6.9L, 7.5L engines) OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Body and Frame > Frame > Subframe > Component Information > Technical Service Bulletins > Suspension - #1 Crossmember Service Replacement Subframe: Technical Service Bulletins Suspension - #1 Crossmember Service Replacement Artile No. 83-18-18 FRAME - #1 CROSSMEMBER - SERVICE REPLACEMENT LIGHT TRUCKS 1980-83 F100-350, BRONCO; 1975-83 ECONOLINE Number 1 crossmember kits are now available for usage where damaged crossmembers require complete replacement. The kits will service all vehicles except HD F-250/350 with 6.9L or 7.5L engines. The kits include detailed installation instructions and necessary fasteners to assure a durable replacement. In instances where the crossmember has minimal damage confined to areas surrounding the pivot brackets, complete replacement may not be required. In these cases, your District Zone Service Manager should be contacted regarding the potential usage of a reinforcing kit instead of complete replacement of the crossmember. PART NUMBER PART NAME CLASS D5UZ-5C139-A Kit - #1 Crossmember C Econoline E0TZ-5C139-A Kit - #1 Crossmember C Bronco, F100-350 (Coil Springs) (except 6.9L, 7.5L engines) E0TZ-5C139-B Kit - #1 Crossmember C F-250/350 (4x4) (leaf springs) (except 6.9L, 7.5L engines) OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Technical Service Bulletins > Customer Interest for Power Door Lock Actuator: > 8871033088 > Mar > 88 > Power Door Locks - Are Inoperative Power Door Lock Actuator: Customer Interest Power Door Locks - Are Inoperative LOCKS - POWER - ROD RETAINER CLIP ASSEMBLY BREAKS OR DISENGAGES POWER DOOR LOCKS - INOPERATIVE - ROD RETAINER CLIP BREAKS OR DISENGAGES Article No. 88-7-1 FORD: 1980-82 GRANADA 1980-83 FAIRMONT 1980-88 MUSTANG, THUNDERBIRD, CROWN VICTORIA 1983-86 LTD 1984-85 ESCORT 1984-88 TEMPO 1986-88 TAURUS LINCOLN-MERCURY: 1980 MONARCH 1980-81 LINCOLN 1980-83 ZEPHYR, MARK VI 1980-86 CAPRI 1980-88 COUGAR, GRAND MARQUIS 1982-88 CONTINENTAL, LINCOLN TOWN CAR 1983-86 MARQUIS 1984-85 LYNX 1984-88 TOPAZ, MARK VII 1986-88 SABLE MERKUR: 1985-88 XR4Ti 1988 SCORPIO LIGHT TRUCK: 1980-88 ECONOLINE 1981-88 F SERIES 1985-86 RANGER, BRONCO II ISSUE: Inoperative power door locks maybe caused by a broken or disengaged lock rod retainer clip assembly. The broken or disengaged retainer clip allows the power lock actuator to disconnect from the actuator rod. ACTION: To correct this, install a new lock rod retainer clip assembly made out of stronger material. Refer to the following removal and installation procedure. 1. Remove door trim panel and water shield. 2. Remove broken or disengaged retainer assembly and replace it with new retainer assembly (E8AZ-5421952-A). NOTE: To prevent damage, make sure the latch assembly is supported from behind before tapping the retainer assembly into the latch assembly. Be careful not to bend the lever of the latch. 3. In some cases, the latch assembly may have to be removed to provide enough space to install the retainer assembly. Refer to Section 44 of the appropriate Shop Manual for latch removal and installation procedures. 4. Reinstall water shield and door trim panel. PART NUMBER PART NAME CLASS E8AZ-5421952-A Retainer Clip Assembly BG OTHER APPLICABLE ARTICLES: 85-12-3 WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Door Lock Actuator: > 8871033088 > Mar > 88 > Power Door Locks - Are Inoperative Power Door Lock Actuator: All Technical Service Bulletins Power Door Locks - Are Inoperative LOCKS - POWER - ROD RETAINER CLIP ASSEMBLY BREAKS OR DISENGAGES POWER DOOR LOCKS - INOPERATIVE - ROD RETAINER CLIP BREAKS OR DISENGAGES Article No. 88-7-1 FORD: 1980-82 GRANADA 1980-83 FAIRMONT 1980-88 MUSTANG, THUNDERBIRD, CROWN VICTORIA 1983-86 LTD 1984-85 ESCORT 1984-88 TEMPO 1986-88 TAURUS LINCOLN-MERCURY: 1980 MONARCH 1980-81 LINCOLN 1980-83 ZEPHYR, MARK VI 1980-86 CAPRI 1980-88 COUGAR, GRAND MARQUIS 1982-88 CONTINENTAL, LINCOLN TOWN CAR 1983-86 MARQUIS 1984-85 LYNX 1984-88 TOPAZ, MARK VII 1986-88 SABLE MERKUR: 1985-88 XR4Ti 1988 SCORPIO LIGHT TRUCK: 1980-88 ECONOLINE 1981-88 F SERIES 1985-86 RANGER, BRONCO II ISSUE: Inoperative power door locks maybe caused by a broken or disengaged lock rod retainer clip assembly. The broken or disengaged retainer clip allows the power lock actuator to disconnect from the actuator rod. ACTION: To correct this, install a new lock rod retainer clip assembly made out of stronger material. Refer to the following removal and installation procedure. 1. Remove door trim panel and water shield. 2. Remove broken or disengaged retainer assembly and replace it with new retainer assembly (E8AZ-5421952-A). NOTE: To prevent damage, make sure the latch assembly is supported from behind before tapping the retainer assembly into the latch assembly. Be careful not to bend the lever of the latch. 3. In some cases, the latch assembly may have to be removed to provide enough space to install the retainer assembly. Refer to Section 44 of the appropriate Shop Manual for latch removal and installation procedures. 4. Reinstall water shield and door trim panel. PART NUMBER PART NAME CLASS E8AZ-5421952-A Retainer Clip Assembly BG OTHER APPLICABLE ARTICLES: 85-12-3 WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Technical Service Bulletins > Page 3130 Power Door Lock Actuator: Locations Inside Doors Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Locations Power Door Lock Relay: Locations Lower LH Cowl Near Fuse Panel Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal Paint: Technical Service Bulletins Paint - Iron Particle Removal Article No. 95-6-1 03/27/95 ^ PAINT - IRON PARTICLE REMOVAL - INDUSTRIAL FALLOUT - ACID RAIN NEUTRALIZATION ^ PAINT - ROUGH TEXTURE/FERROUS METAL CONTAMINATION - ACID RAIN DISCOLORATION OR ETCHING FORD: 1980 and after CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1982-88 EXP 1984-94 TEMPO 1986 and after TAURUS 1988-93 FESTIVA 1989 and after PROBE 1994-95 ASPIRE 1995 CONTOUR LINCOLN-MERCURY: 1980 and after CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1984-92 MARK VII 1984-94 TOPAZ 1986 and after SABLE 1987-89 TRACER 1991-94 CAPRI 1991 and after TRACER 1993 and after MARK VIII 1995 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1980 and after F-150-350 SERIES 1981 and after ECONOLINE 1982 and after BRONCO 1983 and after RANGER 1984-90 BRONCO II 1986 and after AEROSTAR 1988 and after F SUPER DUTY 1991 and after EXPLORER 1993 and after VILLAGER 1995 and after WINDSTAR MEDIUM/HEAVY TRUCK: 1980-91 C SERIES, CL-CLT-9000 SERIES 1980 and after F & B SERIES, L SERIES 1986 and after CARGO SERIES ISSUE: Ferrous metal particles (hot iron dust) are generated by manufacturing facilities, rail shipments, combustion engines, jet engines, body shops, etc. These particles mechanically/magnetically bond to vehicles' painted surfaces. Moisture and temperature combine with the particles to create a chemical reaction. The reaction causes the particles to corrode and enter into the physical paint film. ACTION: To remove these particles/contaminants, USE ONLY the following procedure. The procedure must be performed before any buffing, polishing, color sanding or refinishing is attempted. The materials in this procedure are alkaline, acidic and neutral. They must be used in the specified order. CAUTION: ANY CHANGES TO THIS PROCEDURE WILL CAUSE AN INCOMPLETE OR UNSATISFACTORY REPAIR AND MAY RESULT IN Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 3139 POSSIBLE DAMAGE TO THE PAINTED SURFACES AND TRIM. WARNING: THE TECHNICIAN MUST WEAR PROTECTIVE CLOTHING AND EYE PROTECTION TO PREVENT SKIN IRRITATION. CAUTION: THE USE OF ANY OTHER PRODUCT OR PROCEDURE MAY CAUSE DAMAGE TO ALUMINUM, FLEXIBLE PAINTED SURFACES OR OTHER PAINTED SURFACES. FOLLOW DIRECTIONS EXACTLY AND RINSE THOROUGHLY AFTER EACH STEP. NOTE: THIS DECONTAMINATION PROCEDURE IS DESIGNED TO REMOVE SURFACE CONTAMINANTS FROM THE PAINT ON VEHICLES THAT HAVE BEEN CONTAMINATED UP TO 120 DAYS. VEHICLES WHICH HAVE EXPERIENCED THE CONDITION LONGER THAN THIS PERIOD MAY REQUIRE AN ADDITIONAL TREATMENT TO REMOVE FERROUS METAL CONTAMINANTS. IDENTIFICATION Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 3140 For ease of identifying, the Radio Shack Model 63-851, 30X, lighted, magnifier is recommended. 1. Ferrous Metal ^ Light colored vehicles: Small rust orange dots with black in center of stain. ^ Dark colored vehicles: Small white or silver dots with a "rainbow hue" around the particle. The surface will also feel rough to the touch. 2. Industrial Fallout ^ The surface feels rough to the touch and may exhibit crystalline deposits. ^ Usually ferrous metal is present, as well as water spots. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 3141 3. Acid Rain ^ Surface will exhibit irregular discolored spotting. ^ Dark colored vehicles will show cloudy or greying spots where the acids have started to etch away the paint. NOTE: IN EXTREME CASES ETCHING OF THE SURFACE WILL BE VISIBLE OR FELT. DECONTAMINATION Use Finish Kare Inc. products 1119/883/11850 to decontaminate the paint surface. Follow the manufacturer's recommended procedures. NOTE: FORD DOES NOT RECOMMEND THE USE OF OXALIC ACIDS OR OTHER "FALLOUT REMOVERS". 1. Rinse off dust and debris with cold water. Be sure to start at the bottom and work up. 2. Prepare product "1119" by mixing one (1) part "1119" with four (4) parts cold water. 3. Use clean wash mitt and apply mixture to entire car, starting at the bottom and working up to the top surface. Keep car wet with the solution for 5 to 10 minutes. Do not allow product to dry on the car, and do not allow it to streak down the sides. Rewipe with mitt if necessary to avoid streaks. 4. Rinse car with cold water. 5. Dry the flat surfaces of the vehicle hood, roof and deck lid. 6. Apply product "883" directly to the contaminated surfaces using a clean dry sponge, wash mitt, or soft truck brush ("883" is ready to use from the bottle, with no mixing involved). Keep the areas wet with the "883" for 5 to 7 minutes. Do not allow to dry on the car. Wipe down to the body line on the sides. 7. Prepare product "118SC" by mixing 1 oz (0.03 L) with 1 gal (3.785 L) of water. 8. Shampoo the vehicle with "118SC" shampoo mixture using a clean wash mitt and then rinse with cold water. NOTE: DO NOT USE "1185C" MITT WITH "1119" OR "883" SOLUTIONS. USE SEPARATE MITTS AND ALWAYS KEEP THEM SEPARATE. 9. Inspect paint surface to see if rust particles have been removed. If rust particles have been on the vehicle for a long time, it may be necessary to repeat each of the above steps. NOTE: THE NEUTRALIZER CONCENTRATE IS A HEAVY DUTY SHAMPOO AND CAN BE USED IN AN AUTOMATIC CAR WASH SYSTEM. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 3142 CORRECTION OF SURFACE FOLLOWING DECONTAMINATION: 1. Visually inspect surface for evidence of removal of ferrous metal particles, crystalline deposits and water spots. Acid rain discoloring or etching will require either buffing, color sanding or refinishing if etching is visible. 2. Use the buffing products from only one (1) manufacturer. Do not intermix products. 3. Always follow the manufacturer's product sequence. Use appropriate pads with each product as recommended by the manufacturer. NOTE: DO NOT REMOVE MORE THAN 0.3 OF A MIL OF PAINT MATERIAL, OR REPAINTING WILL BE REQUIRED. 4. Use a dual action sander (D/A Sander) with a velcro-mount backing plate and appropriate foam pad for final polishing swirl removal. 5. Use an alcohol and water mixture (1:4 ratio) to clean buffed areas to verify removal of scratches and swirls before application of final protective glaze. NOTE: FREQUENT WASHING OF VEHICLES IS IMPORTANT. CONTAMINANTS SETTLE ONTO THE VEHICLE EVERY DAY. USE CLEAN WATER (DEIONIZED, REVERSE OSMOSIS, ETC.) TWICE WEEKLY TO REMOVE HEAVY DUST, AND PARTICULATES. THE USE OF A NEUTRAL pH CAR WASH SOAP EVERY TWO (2) WEEKS IS RECOMMENDED TO NEUTRALIZE VEHICLE CONTAMINATION. Parts Block NOTE: DEALERS SHOULD USE PROGRAM CODE R-23 AND CONDITION CODES C5 AND C6. REFER TO W & P MANUAL, SECTION 5-1, PAGE 3. OTHER APPLICABLE ARTICLES: 91-18-1, 92-6-4 WARRANTY STATUS: Eligible Under The Provisions Of 12 Month/12,000 Mile Basic Warranty Coverage OPERATION DESCRIPTION TIME 950601A Decontaminate And Surface 0.6 Hr. Correction - Aspire 950601B Decontaminate And Surface 0.6 Hr. Correction - Escort/Tracer 950601C Decontaminate And Surface 0.6 Hr. Correction - Probe Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 3143 950601D Decontaminate And Surface 0.6 Hr. Correction - Contour/Mystique 950601E Decontaminate And Surface 0.6 Hr. Correction - Mustang 950601F Decontaminate And Surface 0.7 Hr. Correction - Taurus/Sable 950601G Decontaminate And Surface 0.7 Hr. Correction - Thunderbird/Cougar 950601H Decontaminate And Surface 0.7 Hr. Correction - Crown Victoria/Grand Marquis 950601I Decontaminate And Surface 0.7 Hr. Correction - Mark VIII 950601J Decontaminate And Surface 0.7 Hr. Correction - Continental 950601K Decontaminate And Surface 0.6 Hr. Correction - Capri 950601L Decontaminate And Surface 0.8 Hr. Correction - Town Car 950601M Decontaminate And Surface 0.7 Hr. Correction - Villager 950601N Decontaminate And Surface 0.6 Hr. Correction - Windstar 9506010 Decontaminate And Surface 0.7 Hr. Correction - Aerostar 950601P Decontaminate And Surface 0.6 Hr. Correction - Bronco 9506010 Decontaminate And Surface 1.1 Hrs. Correction - Econoline 950601R Decontaminate And Surface 0.9 Hr. Correction - F-Series 950601S Decontaminate And Surface 0.6 Hr. Correction - Explorer 950601T Decontaminate And Surface 0.7 Hr. Correction - Ranger 950601U Decontaminate And Surface 0.5 Hr. Correction - F-Super Duty 950601V Decontaminate And Surface 0.7 Hr. Correction - F/B-Series 950601W Decontaminate And Surface 0.7 Hr. Correction - L-Series 950601X Decontaminate And Surface 0.5 Hr. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 3144 Correction - Cargo 950601Y Decontaminate And Surface 0.6 Hr. Correction - Tempo/Topaz DEALER CODING BASIC PART NO. CONDITION CODE ENTRE C5 OR C6 OASIS CODES: 106000 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 3145 Paint: Technical Service Bulletins Paint - Preparation Procedure And MSDS Information Article No. 94-23-4 11/14/94 PAINT - PRIMED SHEET METAL - PREP PROCEDURE AND MSDS INFORMATION FORD: 1980 and after CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1982-88 EXP 1984 and after TEMPO 1986 and after TAURUS 1988-93 FESTIVA 1989 and after PROBE LINCOLN-MERCURY: 1980 and after CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1984-92 MARK VII 1984 and after TOPAZ 1986 and after SABLE 1987-89 TRACER 1991-94 CAPRI 1993 and after MARK VIII MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1980 and after F-150-350 SERIES 1981 and after ECONOLINE 1982 and after BRONCO 1983 and after RANGER 1984-90 BRONCO II 1986 and after AEROSTAR 1988 and after F SUPER DUTY 1991 and after EXPLORER 1993 and after VILLAGER 1995 WINDSTAR MEDIUM/HEAVY TRUCK: 1980-91 C SERIES, CL-CLT-9000 SERIES 1980 and after F & B SERIES, L SERIES 1986 and after CARGO SERIES ISSUE: This procedure is being published to advise all body and paint technicians about proper procedures for preparation of sheet metal parts coated with electrodeposition primer (E-Coat). ACTION: When prepping a replacement body panel for installation, it is mandatory to leave the E-Coat intact. DO NOT SAND OFF THE E-COAT. Improper preparation with excessive sanding of the E-Coat to bare metal will jeopardize the sheet metal warranty and overall customer satisfaction. In particular, the E-Coat is necessary to protect the parts from rust. Light scuff sanding using a Scotch Brite pad or wet 320 grit sand paper is recommended for minor flaws. If a minor flaw exists, wet sand or scuff out the flaw and prime the repair area. Again, do not remove all of the E-Coat from the panel. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 3146 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 3147 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 3148 WARNING: LEAD CONTAMINATION POTENTIAL: THE ELECTRODEPOSITION PRIMER USED BY FORD MOTOR COMPANY OVER BASE METAL ON SERVICE REPLACEMENT PARTS OR COMPLETED VEHICLES CONTAINS SMALL AMOUNTS OF LEAD FOR CORROSION PROTECTION OF STEEL. EXCESSIVE DUSTS GENERATED BY UNNECESSARY AND IMPROPER SANDING MAY CONTAIN AIRBORNE LEAD CONTAMINATION IN EXCESS OF OSHA STANDARDS. INFORMATION REGARDING THE HAZARDS OF LEAD CAN BE FOUND IN THE CHEMICAL FACT SHEETS IN THE FIGURES IN THIS ARTICLE. NOTE: READ ALL INFORMATION IN THIS TECHNICAL SERVICE BULLETIN CAREFULLY AND FORWARD TO ALL EMPLOYEES PERFORMING PAINT PREPPING OPERATIONS. DEALERS SHOULD CONTACT LEGAL COUNSEL AND/OR LOCAL OSHA Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 3149 AUTHORITIES FOR DIRECTION REGARDING OSHA LEAD STANDARD REQUIREMENTS. If a replacement body panel contains more than a minor flaw in the E-coat, it should be returned. Contact your Customer Service representative for instructions. If more extensive sanding, other than that described above, is necessary, (e.g., refinishing original vehicle sheet metal) follow the procedures outlined below: ALTERNATIVE SANDING PROCEDURES WHEN EXTENSIVE SANDING IS REQUIRED The following procedures for sheet metal preparation by sanding or media blasting are based on tests conducted by Ford Motor Company in accordance with requirements set forth in the Federal OSHA Inorganic Lead Standard 29 CFR 1910.1025. SANDING PROCEDURE 1. Each technician performing the sanding operation MUST wear an approved respirator with high efficiency particulate filter (HEPA). 2. Technicians should use dual action sander with vacuum collection. 3. The vacuum equipment MUST be equipped with a HEPA filter on the air exhaust. Dealers are cautioned not to exhaust vacuum air into the atmosphere. Operators are cautioned to follow the manufacturer's guidelines for maintenance and the replacement of filters. MEDIA BLASTING PROCEDURE 1. Testing has shown that plastic media blasting meets OSHA lead standard requirements and is efficient when the manufacturer's published procedures are followed. 2. The operator must wear an air supplied hood using compressed air free from carbon monoxide, oil, water, and other contamination when performing this operation. Specifics of the media blasting procedure for whole body paint removal have been previously published. NOTE: PLEASE READ THE CHEMICAL FACT SHEETS IN THE FIGURES. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 3150 Paint: Technical Service Bulletins Paint - Cosmetic Surface Service Procedures Article No. 84-3-3 PAINT - COSMETIC SURFACE SERVICE PROCEDURES FORD ALL CAR LINES - ALL MODEL YEARS LINCOLN-MERCURY ALL CAR LINES - ALL MODEL YEARS LIGHT TRUCKS ALL SERIES - ALL MODEL YEARS The cosmetic paint surface service procedures outlined below are reprinted from Article Number 82-3-3 dated February 18, 1982. Many of these procedures and techniques described have been incorporated along with several other helpful procedures in a video tape which is now available. This video tape describes paint and soft facia service procedures developed by Ford Motor Company Assembly plants to correct minor concerns. After seeing the video tape and with practice, a technician or body shop employee should be able to do the following: ^ Remove most minor dings and dents (without filling and repainting), by using special metal massaging service tools. ^ Remove hood and deck depressions without filling and repainting. ^ Remove trapped dirt particles and still preserve the original paint finish. ^ Service minor scratches that do not cut through into the prime or metal. ^ Service orange peel without repainting. ^ Service sags and runs without repainting. ^ Remove surface stains with a heat gun. ^ Make soft facia services on many punctures and tears in plastic parts without replacement. ^ Service damaged abrasion resistant coating. ^ Properly paint over E-coating. The video tape is titled, "Cosmetic Paint and Surface Repairs" and is available in 3/4 inch Umatic UMC, Order Number 4651-025; or 1/2 inch VHS, Order Number 4651-025. For ordering information refer to the Ford Service Training Aids Catalog or write to: Ford Service Publications Post Office Box 07150 Detroit, Michigan 48207 Exterior paint surface damage or imperfections of a nature where the prime coat does not show can, in most instances, be restored without repainting. The restoration of gloss and luster after the condition has been removed is made possible by new and improved service materials and procedures. The following procedure is applicable to surface conditions such as dirt particles, orange peel, runs, sags, industrial fallout stains, swirl marks, light scratches and other minor imperfections. Usually, these conditions are localized and it is not necessary to restore the entire panel. However, in a case such as dirt particles or scratches in several localized areas, it is recommended that the entire panel be restored to maintain a uniform appearance. FIGURE 5 Preparation Before starting the service, the affected surface must be clean and dry. Mask off adjacent panels, mouldings, stripes and character lines as required (Figure 5). Where applicable, eye protection, face mask and a belt buckle cover should be worn. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 3151 Service Procedure The basic concept of the procedure is to remove the defect condition, and then restore the finish to an acceptable appearance. As a general guideline, remember that sanding marks are removed with rubbing compound and the swirl marks evident after buffing are removed by polishing. As an example, light scratches or small dirt particles can be removed with a power buffer and medium buffing compound followed by polishing. Deeper scratches, heavy dirt particles or orange peel must be wet sanded, buffed with compound to remove the sanding marks and then polished to remove the swirl marks from the buffing operation. It is suggested with initial service attempts, that technicians develop a learning cycle by picking a small service area and first try polishing, then buffing and finally wet sanding to remove the condition. When you have determined which method is appropriate, proceed with the remaining area to be serviced and then restore the finish as required. The following outlines the complete procedure and required materials. FIGURE 6 Polishing For removal of very minor scratches, swirl marks and/or to restore luster to a dull finish. Apply a small amount of 3M Final Glaze to the affected panel (Figure 6) and using a suitable electric or air powered polish/buffing wheel (2000 max. rpm) and a 3M Superbuff 2 + 2 Pad, polish the affected area until all swirl marks are gone and desired luster is obtained. When polishing, keep the pad flat against the surface. Do not bear down, the weight of the buffer is sufficient. Add Final Glaze sparingly as needed. Compound For removal of light scratches, small dirt particles, minor grind marks and sanding marks. FIGURE 7 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 3152 FIGURE 8 Apply 3M Superduty Rubbing Compound (medium) to the panel and using a clean 2 + 2 pad on the wheel (as noted above) spread the compound evenly and buff the surface until the condition is removed; or in the case of a sanded area, the sanding marks are gone and the luster is restored to an acceptable level for polishing (Figure 7 and Figure 8). When buffing, keep the wheel flat to the surface using light to moderate pressure and long even strokes. Periodically check the finish and add compound as required. When buffing is complete, polish the panel as described above. Sanding For removal of severe conditions such as heavy dirt particles, deep scratches and orange peel. This wet sanding procedure utilizes 3M Ultra Fine Imperial Wetordry Color Sanding Paper to facilitate removal of surface damage. The Ultra Fine paper cuts quickly leaving a uniform finish that requires a minimum of buffing to restore the luster. FIGURE 9 1. Soak the 3M Imperial Wetordry Paper and a 3M Imperial Wetordry Sponge Pad thoroughly in clean water and wrap the paper around the pad as shown in Figure 9. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 3153 FIGURE 10 2. Using a clean sponge, wet the area to be sanded. It is essential that the paper be kept wet as sanding proceeds (Figure 10). FIGURE 11 3. Wet sand the affected area with light even pressure on the pad with back and forth strokes (not circular). Do a small area at a time (Figure 11). FIGURE 12 4. Frequently dip the pad and paper in water to wash off sanding residue (Figure 12). Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 3154 FIGURE 13 5. Frequently flood or squeegee off the affected surface to check depth of cut and to see if the defect is removed. The amount of paint surface that is being sanded can be judged as the area dulls (Figure 13). FIGURE 14 6. Water wash the affected area to determine if all surface defects have been removed. Note the uniform dull appearance of an evenly sanded panel (Figure 14). If the surface is not uniform, lightly resand the area. FIGURE 15 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 3155 7. Wash and squeegee off the panel and check to assure that all defects are removed and sanding is complete. Then proceed with the buffing and polish procedures to restore the luster to the finish. 8. Figure 15 shows a hood panel which has been sanded, buffed and polished on one section to illustrate the effectiveness of the procedure. Runs and Sags The service of runs and sags in nonmetallic paint is covered in the previously released training publication "The Wet Look." This procedure, which consists of shaving the run or sag flush with a commercial single edge razor blade, sanding with a hard block and then compounding, can now be improved by finishing the service with Final Glaze. It is recommended that minor sags and runs be wet sanded with 600 grit paper. If it is necessary to shave them off with a razor blade, first dull the corners with sandpaper to avoid scratching the adjacent panel finish. PART NUMBER PART NAME CLASS 05528 3M Imperial Wetordry Sponge Pad 02021 3M Imperial Wetordry Color Sanding Paper 05955 3M Superduty Rubbing Compound 05957 3M Superduty Paste Compound (if preferred) 05701 3M Superbuff 2 + 2 Pad 05710 3M Superbuff Adaptor (if req'd) 05988 3M Final Glaze 02024 3M Wetordry Tri-M-ite Paper 600 Grit 05519 3M Sanding Block 7" Polisher/Buffer Air or Electric Razor Blade - Industrial Single Edge OTHER APPLICABLE ARTICLES: 82-3-3 WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: SPP6282 TIME: One Panel 0.4 Hr. - Each additional 0.2 Hr. MATERIAL ALLOWANCE: $.75 per panel DLR. CODING: Basic Part No. As applicable Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 3156 Paint: Technical Service Bulletins Paint - Cosmetic Damage From Airborn Materials PAINT COSMETIC DAMAGE FROM AIRBORN MATERIALS Article No. 89-13-3 FORD: 1989 and prior ALL FORD LINES LINCOLN-MERCURY: 1989 and prior ALL LINCOLN-MERCURY LINES LIGHT TRUCK: 1989 and prior ALL LIGHT TRUCK LINES ISSUE: Paint may be damaged from various sources of airborn materials. The two different types are: ^ Inorganic ^ Organic Sometimes it is hard to identify the type of paint damage and know how to remove it. This TSB article gives detailed information and descriptions of both types of airborn materials. It also outlines the service procedures for treating them. ACTION: If service is required, identify the source of damage involved by referring to the following information. Use the following recommended service procedure to correct concerns. INORGANIC AIRBORN MATERIAL The effects of inorganic airborn materials can be seen as: ^ Dark blotches in the paint where the pigment in the paint surface has been attacked ^ Irregular spots that are cracked or etched around the edges and dull in the centers. ^ Small orange colored spots caused by iron particles may appear on the paint surface. Generally, materials that attack a paint film are either acidic or alkaline in nature. Sulfuric and nitric acids, in general, cause extreme damage to automative paint finishes. Even very small concentrations of the same materials can cause chemical spotting damage. Due to evaporation and condensation, these acids can create severe etching "spots" that may eventually crack or lift the paint film after some time in service. Although some automotive finishes are more resistant than others, none are completely immune to these chemicals. The most resistant paints used today are the urethanes because their resin system is least likely to react with chemicals. Air dry coatings are more susceptible to attack only when they are fresh. The longer the paint dries the more resistant it becomes. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 3157 Metallic colors are more intolerant to chemicals because aluminum flake is fairly reactive with either an acid or alkali. The following chart contains the most common acid materials found on automotive finishes. The chart shows a color, the corresponding damage appearance and also the chemical causal agent. It is not applicable for Basecoat/Clearcoat finishes. * "Caustic" refers to any alkaline substance that may be "harsh" or "corrosive" depending on strength or concentration. The following "pH" chart show the relationship between acidic and alkaline chemicals and their corresponding pH values. This chart is provided for informational reference only. ORGANIC AIRBORN MATERIALS Organic damage is generally easier to identify. Organic damage is mostly due to tree sap, bird and insect droppings, dead insects (Figure 8) and pollen. Tree sap is easily identified by clear raised drops that may be hard or sticky. Bee or bug dropping spots may appear brownish or yellow in color, about an eighth to a quarter inch in diameter. Dead and decomposing insect bodies are readily visible to the eye. Pollen deposits are small yellow clusters. Each of these items is potentially damaging to any currently available paint system. Other noticeable traits of organic damage are spots that are raised (swelling) micro-crazing (cracked) and pitting, due to pollen eating into the paint film. The active ingredients in most organic contaminants are tannic and formic acids . These acids are found in berries and bodily fluids of insects and birds. Investigations completed at dealerships show that the bright lot lights tend to attract insects. The use of "soft lights" for display and storage lot illumination will help reduce damage resulting from decomposing bugs and droppings by decreasing the number of bugs attracted to these lights. Organic damage is accelerated by heat. During very hot weather conditions, it is important to wash vehicles more often. ORGANIC AND INORGANIC REPAIR PROCEDURES FOR MILD DAMAGE Iron dust particles may imbed themselves into the paint film. On some light colored vehicles after some weathering, tiny dots of rust start to appear. They Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 3158 feel rough to the touch and are difficult to remove. The best way to remove these particles is by treating the finish with an oxalic acid-detergent-water wash. Use the following procedure to perform this service repair. NOTE: OXALIC ACID WASH IS ALSO PRE-PACKAGED IN VARIOUS STRENGTHS UNDER VARIOUS BRAND NAMES, IF YOU CHOOSE NOT TO MIX YOUR OWN BATCHES. 1. Wash and degrease the vehicle first, using Ford Multi Purpose Cleaner (B8A-19523-B) or equivalent, and a suitable wax and grease remover. If this does not remove all of the iron particles, proceed with the oxalic acid wash. 2. Prepare a quantity of oxalic acid-detergent-water solution as follows: a. Dissolve 6-8 ounces of Oxalic Acid (powder) in one gallon of warm water. b. Add 1-2 tablespoons full of non-alkaline detergent such as Ford Multi Purpose Cleaner. 3. Apply this solution liberally to all affected surfaces of the vehicle with a large sponge. Keep the surface wet until the technician can no longer feel any surface roughness with bare or gloved fingertips. NOTE: IF THIS IS NOT DONE THOROUGHLY, STAINING MAY REDEVELOP IF IRON PARTICLES ARE LEFT BEHIND. 4. Rinse the area with clean water. CAUTION: FAILURE TO THOROUGHLY RINSE THIS SURFACE COULD RESULT IN CORROSION OF ANODIZED ALUMINUM OR STAINLESS STEEL PARTS WITH PROLONGED CONTACT. 5. If the iron particles are not totally removed after 2 washings, use one or both of the procedures listed for minor chemical contamination. NOTE: THE USE OF POLISHING (WITH WAX), SANDING WITH MICRO FINE SANDPAPER (1500 GRIT OR GREATER) OR BUFFING WITH VERY LIGHT COMPOUND SHOULD ONLY BE DONE AS A LAST RESORT. CHEMICAL CONTAMINATION Chemical contamination, either acid or alkali, can cause off-color spots and crack the paint film. In the presence of moisture (dew), sulfur contamination will change the color (light/dark) of the paint pigments. (This does not apply to Basecoat/Clearcoat) Since this contamination affects the pigments, lacquers and enamels show no difference in resistance. Production thermal drying and air drying finishes are likely to be spotted. Minor chemical contamination can be removed by using the following step by step procedure. 1. Wash the vehicle first by using Ford Multi Purpose Cleaner (B8A-19523-B) or equivalent to remove the exterior foreign materials. 2. If the spotting is extensive and on the horizontal surfaces, then machine polish. 3. Apply a light grit polishing compound to the affected surface by using a soft brush. The compound should be applied to a small area at a time so that it can be buffed out while still wet to get maximum cutting efficiency. 4. Polish off the spots using a buffer operating at 1700-1800 rpm. Confine polishing to the spotted areas. Repeat as necessary until all spots have been removed. 5. Remove spots on curved surfaces, near edges, and next to mouldings or ornaments by hand polishing as follows: a. Apply some polishing compound to a cotton cloth. (Do not use a synthetic cloth.) b. Rub vigorously until the spots are no longer visible. c. Clean off excess polishing compound by using a clean cloth and compressed air. 6. Buff out the polishing marks and bring up the gloss by using a buffer equipped with a clean, dry lambs wool pad. NOTE: IF POLISHING DOES NOT SUFFICIENTLY REMOVE DAMAGE, THE VEHICLE CAN BE WET SANDED USING 1500 GRIT SANDPAPER AND THE FOLLOWING PROCEDURE Wet Sanding Procedure 1. Clean the exterior surface of the vehicle with Ford Multi Purpose cleaner or an equivalent to remove all contamination. 2. Apply 1500 grit sandpaper to a rubber padded sanding block to sand the paint surface. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 3159 3. Use a squirt bottle filled with water to lubricate the 1500 grit sandpaper as you begin to sand only the damaged areas. Water is an abrasive as well as a lubricant in this step. NOTE: IF THE DAMAGE HAS GONE DEEPLY INTO THE PAINT FILM AND IT WILL NOT POLISH OR SAND OUT, THEN REFINISHING IS REQUIRED. ORGANIC MATERIAL REPAIR PROCEDURE FOR MILD DAMAGE Minor organic damage can be removed by using the following step by step procedure. 1. Wash and degrease the vehicle thoroughly by using Ford Multi Purpose Cleaner (B8A-19523-B) or equivalent and a wax and grease remover to remove all organics. 2. Inspect the vehicle horizontal surfaces. If spotting or paint film swelling is extensive, use a buffer to repair. 3. Apply a light grit polishing compound to the affected areas by using a soft brush. The compound should be applied to a small area at a time so that it can be buffed out while still wet to get maximum efficiency. 4. Polish off the spots or swelling marks using a buffer that operates between 1700-1800 rpm. Polishing should be confined to the affected areas only. Repeat as necessary until all spots or marks are removed. 5. Remove spots on curved surfaces, near edges, and next to mouldings or ornaments by hand polishing as follows: a. Apply some polishing compound to a cotton cloth. (Do not use a synthetic cloth.) b. Rub vigorously until the spots are no longer visible. c. Clean off excess polishing compound by using a clean cloth and compressed air. 6. Buff out the polishing marks and bring up the gloss by using a buffer equipped with a clean, dry lambs wool pad. NOTE: IF POLISHING DOES NOT SUFFICIENTLY REMOVE DAMAGE, THE VEHICLE CAN BE WET SANDED USING 1500 GRIT SANDPAPER AND THE FOLLOWING PROCEDURE. Wet Sanding Procedure 1. Clean the exterior surface of the vehicle with Ford Multi Purpose cleaner or an equivalent to remove all organics. 2. Apply 1500 grit sandpaper to a rubber padded sanding block to sand the paint surface. 3. Use a squirt bottle filled with water to lubricate the 1500 grit sandpaper as you begin to sand only the damaged areas. Water is an abrasive as well as a lubricant in this step. NOTE: IF THE DAMAGE HAS GONE DEEPLY INTO THE PAINT FILM AND IT WILL NOT POLISH OUT, THEN REFINISHING IS REQUIRED. PAINT RECONDITIONING PROCEDURES FOR SEVERE DAMAGE Acrylic enamel single stage or base/clear paint systems should be painted by using the following procedure. 1. .Wash the vehicle with Ford Multi Purpose Cleaner or equivalent to remove all organic materials. 2. Wash the areas to be painted with wax and grease remover. 3. Prepare the area as follows: a. Neutralize the affected areas with baking soda (sodium bicarbonate) and water. b. Rinse the surface off with plain water. c. Wash the panel with a mild soapy detergent. d. Dry the panel completely. NOTE: IF THE DAMAGE IS THROUGH THE TOP COAT FINISH AND INTO THE PRIMERS, THE PANEL MUST BE SANDED DOWN TO BARE METAL OR PLASTIC AND THEN REFINISHED. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Paint - Iron Particle Removal > Page 3160 4. Apply a self-etching primer for metal surfaces only. NOTE: A FLEX ADDITIVE MAY BE NECESSARY WHEN WORKING WITH FLEXIBLE PLASTICS Then proceed as follows: a. Let dry per instructions. b. Apply a two component urethane primer surfacer. c. Sand the surface with 400 grit sandpaper to get to proper finish. d. Finish sanding with 600 grit sandpaper. 5. Solvent wash panel with wax and grease remover. Then, tack wipe it. 6. Apply base coat or top coat material per applicable paint system. NOTE: THE USE OF ACRYLIC URETHANE ENAMEL IS HIGHLY RECOMMENDED FOR THIS TYPE OF REPAIR. 7. Apply clear acrylic urethane if you are using a base/clear paint system. WAYS TO MINIMIZE EFFECTS OF AIRBORN MATERIAL DAMAGE During the past year, Ford Motor Company and major paint suppliers have participated in a survey to analyze the effects of airborn materials. This survey was conducted on foreign and domestic vehicles. It resulted in the following interesting conclusions. 1. Keeping the vehicles clean, washing frequently with de-ionized water and drying by hand or mechanical means will help minimize the effects of inorganic and organic materials. 2. Spray washing without rubbing will not totally remove all residue on the surface of the vehicle. Damage could possibly occur over a longer period of time. 3. Care should be taken to not allow any painted vehicle surface to become wet in direct sunlight. (A sprinkler system can cause damage if the vehicles are not dried.) Possible alkaline water or mineral deposit may be the cause. 4. The use of "Soft Lights" for lighting around storage lots and showing areas will minimize the attraction of insects and the possibility of organic damage. 5. Ford Motor Company is piloting a program for a transit/storage coating to be applied on the horizontal surfaces of all vehicles. These coatings have shown good protection to the paint surface. They are clear in color and should be left on the vehicles until they are sold. 6. We are testing many "permanent paint sealants" used by dealers. Until all testing is completed, we cannot give any recommendations for what products to use. Testing has shown that a sealant that allows water to bead up on the vehicle does not help to dissipate the materials on the paint surface. Sheeting of water on the vehicle is highly desirable. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 1100 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Locations Power Door Lock Relay: Locations Lower LH Cowl Near Fuse Panel Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Testing and Inspection Brake Switch (Cruise Control): Testing and Inspection Perform this test only when brake application will not disconnect the speed control system. 1. Check operation of stop lamps by applying approximately 6 lbs. of pressure to brake pedal. If more than 6 lbs. is required, check brake pedal actuation and stop lamp switch. 2. If stop lamps do not function properly, check bulbs, circuit fuse or stop lamp switch. 3. If stop lamps function properly, check for battery voltage at 6 way connector using black wire w/green stripe on 1980 models, 1981-83 E-100-350 and 1984-87 E-150-350 series, or white wire w/pink stripe on 1981-82 F-100-350 and Bronco series, or white wire w/purple stripe on 1983 F-100-350, Bronco and Ranger, 1984-87 F-150-350, Ranger, 1984-87 Bronco II and 1986-87 Aerostar. 4. Depress brake pedal until stop lamps are illuminated. Check voltage at red wire w/black stripe on 1980 models, 1981-83 E-100-350 and 1984-87 E-150-350 models, or the light green wire on 1981-83 F-100-350 and Bronco, 1984-87 F-150-350 and Bronco, 1983-87 Ranger, 1984-87 Bronco II and 1986-87 Aerostar. The difference between the two voltage readings must not exceed 1.5 volts. If voltage is greater, a high resistance exists in the circuit and must be found and corrected. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Service and Repair Clutch Switch: Service and Repair 1. Remove bracket mounting screw(s). 2. Disconnect electrical connector and remove switch and bracket assembly. 3. Remove switch from bracket. 4. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations Cruise Control Module: Locations LH Side Of I/P Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations > Page 3175 Cruise Control Module: Testing and Inspection Use only a multi-meter of 5000 ohm/volt rating or higher when performing amplifier test. ``On'' Circuit Test 1. Turn ignition ``On.'' 2. Connect a voltmeter between light blue wire w/black hash and ground on models exc. 1983-87 Ranger, 1984-87 Bronco II and 1986-87 Aerostar or white wire w/purple stripe and ground on 1983-87 Ranger, 1984-87 Bronco II and 1986-87 Aerostar. 3. Battery voltage should be indicated when ``On'' switch on steering column is depressed and held. If battery voltage is not indicated, check horn relay and perform control switch test. 4. Release ``On'' button. Voltmeter should indicate 7.8 volts indicating ``On'' circuit is engaged. If voltage does not remain, check amplifier ground, fuses or circuit breakers or replace amplifier with known good amplifier and repeat test. 5. Replace as necessary. ``Off'' Circuit Test 1. Turn ignition ``On.'' 2. Connect a voltmeter between light blue wire w/black hash and ground. 3. Depress ``Off'' button. Voltage should drop to zero indicating ``On'' circuit is de-energized. 4. If voltage does not drop to zero, perform ``Control Switch Test.'' ``Set-Accelerate'' Circuit Test 1. Turn ignition ``On.'' 2. Connect a voltmeter between light blue wire w/black hash and ground. 3. Depress ``On'' switch, then hold ``Set-Accel'' button on steering wheel. Voltmeter should indicate 4.5 volts. Rotate steering wheel back and forth and check for voltmeter fluctuations. If reading varies more than .5 volts, perform ``Control Switch Test.'' ``Coast'' Circuit Test 1. Turn ignition ``On.'' 2. Connect a voltmeter between light blue wire w/black hash and ground. 3. Depress ``On'' switch, then depress and hold ``Coast'' button on steering wheel. Voltmeter should indicate 1.5 volts. Rotate steering wheel back and forth and check for voltage fluctuations. If reading varies more than .5 volts, perform ``Control Switch Test.'' ``Resume'' Circuit Test 1. Turn ignition ``On.'' 2. Connect a voltmeter between light blue wire w/black hash and ground. 3. Depress and hold ``Resume'' button. Voltmeter should indicate 6.5 volts. If all circuits are functioning properly, perform ``Servo Assembly Test'' using a known good amplifier. Do not replace amplifier before performing servo test. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations Cruise Control Servo: Locations RH Rear Of Engine Compartment RH Side Of Engine Compartment Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 3179 Cruise Control Servo: Testing and Inspection 1981-83 F-100-350 & Bronco, 1984-87 F-150-350 & Bronco 1982-83 E-100-350 & 1984-87 E-150-350 Series 1. Disconnect ball chain from carburetor (if equipped), then the electrical connector at the amplifier. 2. Connect an ohmmeter between orange wire w/yellow hash and gray wire w/black hash at connector. A resistance of 40 to 125 ohms should be obtained. 3. Connect an ohmmeter between orange wire w/yellow hash and white wire w/pink hash. A resistance of 60 to 90 ohms should be obtained. 4. If equipped, connect ball chain to carburetor. 5. Start engine and ensure servo vacuum from engine exceeds 2.5 inches of Hg, then disconnect servo from amplifier. 6. Connect orange wire w/yellow hash of servo to battery positive terminal and white wire w/pink hash to ground, then momentarily touch gray wire w/black hash to ground. Servo throttle actuator should pull in and engine RPM should increase. Throttle should hold in position or slowly release chain tension. 7. Remove white wire w/pink hash and check for immediate release of chain tension from servo. 8. Replace servo if servo fails to function as described. Amplifier may need replacement if orange wire w/yellow hash is shorted to either white-pink hash lead or gray-black hash lead. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 3180 Cruise Control Servo: Service and Repair Exc. 1986-87 Aerostar 1. Raise hood, then disconnect wiring harness connector at servo assembly. On some models, it may be necessary to disconnect servo assembly at the amplifier under the dash and carefully pull harness and connector through dash panel opening. 2. Disconnect ball chain at carburetor or adjuster from accelerator cable (as equipped), then remove vacuum hose from servo assembly. 3. Remove servo assembly retaining pins and nuts, then the servo assembly from mounting bracket. 4. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service and Repair Cruise Control Servo Cable: Service and Repair 1. Remove servo assembly, then discard cable. 2. Attach new actuator cable to servo assembly. 3. Install servo assembly. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations Cruise Control Switch: Locations On Steering Wheel Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 3187 Cruise Control Switch: Testing and Inspection 1980-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986 Aerostar Disconnect 6 way connector from control switch at the amplifier, then perform the following checks: 1. Connect a voltmeter between light blue-black hash lead and ground, then depress the ``On'' button and check for battery voltage. 2. Turn ignition ``Off,'' then connect an ohmmeter between light blue-black hash lead and ground. 3. Rotate steering wheel throughout its full range while making the following checks: a. Depress ``Off'' button and check for a reading of 0-1 ohm. b. Depress ``Set'' button and check for a reading of 646-714 ohms. c. Depress and hold ``Coast'' switch and check for a reading of 114-126 ohms. d. On models with ``Resume,'' depress and hold ``Resume'' switch and check for a reading of approximately 2200 ohms. 4. If resistance values are not as specified, inspect wiring, slip rings, turn signal copper brushes, speed control switch and steering column for proper ground. Check for proper ground by connecting an ohmmeter between upper steering column flange and a suitable ground. Resistance should be less then 1/2 ohm. Rotate steering wheel throughout its full range and ensure flexible coupling has a resistance of less than 1 ohm. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 3188 Cruise Control Switch: Service and Repair 1. Remove steering wheel pad attaching screws from behind steering wheel. 2. While pulling pad away from steering wheel, disconnect horn and speed control wire connectors and remove pad. 3. Remove retaining nuts securing the speed control switches and trim plate retainer to the steering wheel pad. 4. Disconnect wiring connector on rear of steering wheel pad assembly, then remove switch and trim retainer assembly. 5. Remove speed control switches by snapping out of plastic retainer. 6. To remove the ground brush, remove steering wheel for access. 7. Snap the ground brush assembly out of the turn signal switch. 8. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Cruise Control > Cruise Control Vacuum Vent Solenoid > Component Information > Locations Cruise Control Vacuum Vent Solenoid: Locations Top Of Brake Pedal Support Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations Cruise Control Module: Locations LH Side Of I/P Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 3196 Cruise Control Module: Testing and Inspection Use only a multi-meter of 5000 ohm/volt rating or higher when performing amplifier test. ``On'' Circuit Test 1. Turn ignition ``On.'' 2. Connect a voltmeter between light blue wire w/black hash and ground on models exc. 1983-87 Ranger, 1984-87 Bronco II and 1986-87 Aerostar or white wire w/purple stripe and ground on 1983-87 Ranger, 1984-87 Bronco II and 1986-87 Aerostar. 3. Battery voltage should be indicated when ``On'' switch on steering column is depressed and held. If battery voltage is not indicated, check horn relay and perform control switch test. 4. Release ``On'' button. Voltmeter should indicate 7.8 volts indicating ``On'' circuit is engaged. If voltage does not remain, check amplifier ground, fuses or circuit breakers or replace amplifier with known good amplifier and repeat test. 5. Replace as necessary. ``Off'' Circuit Test 1. Turn ignition ``On.'' 2. Connect a voltmeter between light blue wire w/black hash and ground. 3. Depress ``Off'' button. Voltage should drop to zero indicating ``On'' circuit is de-energized. 4. If voltage does not drop to zero, perform ``Control Switch Test.'' ``Set-Accelerate'' Circuit Test 1. Turn ignition ``On.'' 2. Connect a voltmeter between light blue wire w/black hash and ground. 3. Depress ``On'' switch, then hold ``Set-Accel'' button on steering wheel. Voltmeter should indicate 4.5 volts. Rotate steering wheel back and forth and check for voltmeter fluctuations. If reading varies more than .5 volts, perform ``Control Switch Test.'' ``Coast'' Circuit Test 1. Turn ignition ``On.'' 2. Connect a voltmeter between light blue wire w/black hash and ground. 3. Depress ``On'' switch, then depress and hold ``Coast'' button on steering wheel. Voltmeter should indicate 1.5 volts. Rotate steering wheel back and forth and check for voltage fluctuations. If reading varies more than .5 volts, perform ``Control Switch Test.'' ``Resume'' Circuit Test 1. Turn ignition ``On.'' 2. Connect a voltmeter between light blue wire w/black hash and ground. 3. Depress and hold ``Resume'' button. Voltmeter should indicate 6.5 volts. If all circuits are functioning properly, perform ``Servo Assembly Test'' using a known good amplifier. Do not replace amplifier before performing servo test. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Testing and Inspection Brake Switch (Cruise Control): Testing and Inspection Perform this test only when brake application will not disconnect the speed control system. 1. Check operation of stop lamps by applying approximately 6 lbs. of pressure to brake pedal. If more than 6 lbs. is required, check brake pedal actuation and stop lamp switch. 2. If stop lamps do not function properly, check bulbs, circuit fuse or stop lamp switch. 3. If stop lamps function properly, check for battery voltage at 6 way connector using black wire w/green stripe on 1980 models, 1981-83 E-100-350 and 1984-87 E-150-350 series, or white wire w/pink stripe on 1981-82 F-100-350 and Bronco series, or white wire w/purple stripe on 1983 F-100-350, Bronco and Ranger, 1984-87 F-150-350, Ranger, 1984-87 Bronco II and 1986-87 Aerostar. 4. Depress brake pedal until stop lamps are illuminated. Check voltage at red wire w/black stripe on 1980 models, 1981-83 E-100-350 and 1984-87 E-150-350 models, or the light green wire on 1981-83 F-100-350 and Bronco, 1984-87 F-150-350 and Bronco, 1983-87 Ranger, 1984-87 Bronco II and 1986-87 Aerostar. The difference between the two voltage readings must not exceed 1.5 volts. If voltage is greater, a high resistance exists in the circuit and must be found and corrected. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Service and Repair Clutch Switch: Service and Repair 1. Remove bracket mounting screw(s). 2. Disconnect electrical connector and remove switch and bracket assembly. 3. Remove switch from bracket. 4. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations Cruise Control Switch: Locations On Steering Wheel Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 3207 Cruise Control Switch: Testing and Inspection 1980-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986 Aerostar Disconnect 6 way connector from control switch at the amplifier, then perform the following checks: 1. Connect a voltmeter between light blue-black hash lead and ground, then depress the ``On'' button and check for battery voltage. 2. Turn ignition ``Off,'' then connect an ohmmeter between light blue-black hash lead and ground. 3. Rotate steering wheel throughout its full range while making the following checks: a. Depress ``Off'' button and check for a reading of 0-1 ohm. b. Depress ``Set'' button and check for a reading of 646-714 ohms. c. Depress and hold ``Coast'' switch and check for a reading of 114-126 ohms. d. On models with ``Resume,'' depress and hold ``Resume'' switch and check for a reading of approximately 2200 ohms. 4. If resistance values are not as specified, inspect wiring, slip rings, turn signal copper brushes, speed control switch and steering column for proper ground. Check for proper ground by connecting an ohmmeter between upper steering column flange and a suitable ground. Resistance should be less then 1/2 ohm. Rotate steering wheel throughout its full range and ensure flexible coupling has a resistance of less than 1 ohm. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 3208 Cruise Control Switch: Service and Repair 1. Remove steering wheel pad attaching screws from behind steering wheel. 2. While pulling pad away from steering wheel, disconnect horn and speed control wire connectors and remove pad. 3. Remove retaining nuts securing the speed control switches and trim plate retainer to the steering wheel pad. 4. Disconnect wiring connector on rear of steering wheel pad assembly, then remove switch and trim retainer assembly. 5. Remove speed control switches by snapping out of plastic retainer. 6. To remove the ground brush, remove steering wheel for access. 7. Snap the ground brush assembly out of the turn signal switch. 8. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer Cruise Control > Component Information > Testing and Inspection Vehicle Speed Sensor/Transducer - Cruise Control: Testing and Inspection 1980-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986-87 Aerostar 1. Disconnect 6 way connector from amplifier assembly, then connect an ohmmeter between dark green wire w/white stripe and black wire on 1980 E-100-350, 1981-83 F-100-350 models and Bronco, and 1984-87 F-150-350 and Bronco, or green and black wire on 1980 F-100-350 and 1981-83 E-100-350 models and 1984-87 E-150-350 at the speed sensor end. A reading of 40 ohms should be obtained. A reading of 0 ohms indicates a shorted coil and an infinity reading indicates an open coil. 2. Replace sensor if a correct reading has not been obtained. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Cruise Control > Vacuum Vent Valve, Cruise Control > Component Information > Testing and Inspection Vacuum Vent Valve: Testing and Inspection 1. Disconnect vacuum hose from the servo that leads to the dump valve. 2. Connect a hand vacuum pump to the hose, and draw vacuum. If vacuum cannot be obtained, the hose or dump valve is leaking, and should be replaced. 3. Step on brake pedal. The vacuum should be released. If not, adjust or replace the dump valve. 2.5 inches of Hg is minimum vacuum for normal servo operation. The vacuum source is a hose attached to a 5/16 inch engine vacuum fitting port on all except 6.9 diesel. On the 6.9 diesel, the vacuum source is the vacuum reservoir ``Vac'' port. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Cruise Control > Vacuum Vent Valve, Cruise Control > Component Information > Testing and Inspection > Page 3215 Vacuum Vent Valve: Service and Repair 1. Remove vacuum hose from valve and remove bracket mounting screw. 2. Remove valve and bracket assembly. 3. Remove valve from the bracket. 4. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information > Testing and Inspection Vehicle Speed Sensor/Transducer - Cruise Control: Testing and Inspection 1980-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986-87 Aerostar 1. Disconnect 6 way connector from amplifier assembly, then connect an ohmmeter between dark green wire w/white stripe and black wire on 1980 E-100-350, 1981-83 F-100-350 models and Bronco, and 1984-87 F-150-350 and Bronco, or green and black wire on 1980 F-100-350 and 1981-83 E-100-350 models and 1984-87 E-150-350 at the speed sensor end. A reading of 40 ohms should be obtained. A reading of 0 ohms indicates a shorted coil and an infinity reading indicates an open coil. 2. Replace sensor if a correct reading has not been obtained. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Ammeter Gauge > Component Information > Testing and Inspection Ammeter Gauge: Testing and Inspection The ammeter is an instrument used to indicate current flow into and out of the battery. When electrical accessories in the vehicle draw more current than the alternator can supply, current flows from the battery and the ammeter indicates a discharge ( - ) condition. When electrical loads of the vehicle are less than alternator output, current is available to charge the battery, and the ammeter indicates a charge (+) condition. If battery is fully charged, the voltage regulator reduces alternator output to meet only immediate vehicle electrical loads. When this happens, ammeter reads zero. Fig. 1 Conventional type ammeter CONVENTIONAL AMMETER A conventional ammeter must be connected between the battery and alternator in order to indicate current flow. This type ammeter, Fig. 1, consists of a frame to which a permanent magnet is attached. The frame also supports an armature and pointer assembly. Current in this system flows from the alternator through the ammeter, then to the battery or from the battery through the ammeter into the vehicle electrical system, depending on vehicle operating conditions. When no current flows through the ammeter, the magnet holds the pointer armature so that the pointer stands at the center of the dial. When current passes in either direction through the ammeter, the resulting magnetic field attracts the armature away from the effect of the permanent magnet, thus giving a reading proportional to the strength of the current flowing. Troubleshooting When the ammeter apparently fails to register correctly, there may be trouble in the wiring which connects the ammeter to the alternator and battery or in the alternator or battery itself. To check the connections, first tighten the two terminal posts on the back of the ammeter. Then, following each wire from the ammeter, tighten all connections on the ignition switch, battery and alternator. Chafed, burned or broken insulation can be found by following each ammeter wire from end to end. All wires with chafed, burned or broken insulation should be repaired or replaced. After this is done, and all connections are tightened, connect the battery cable and turn on the ignition switch. The needle should point slightly to the discharge ( - ) side. Start the engine and run slightly above idling speed. The needle should move slowly to the charge side (+). If the pointer does not move as indicated, the ammeter is out of order and should be replaced. SHUNT TYPE AMMETER The shunt type ammeter is actually a specifically calibrated voltmeter. It is connected to read voltage drop across a resistance wire (shunt) between the battery and alternator. The shunt is located either in the vehicle wiring or within the ammeter itself. When voltage is higher at the alternator end of the shunt, the meter indicates a charge (+) condition. When voltage is higher at the battery end of the shunt, the meter indicates a discharge ( - ) condition. When voltage is equal at both ends of the shunt, the meter reads zero. Troubleshooting Ammeter accuracy can be determined by comparing reading with an ammeter of known accuracy. 1. With engine stopped and ignition switch in RUN position, switch on headlamps and heater fan. Meter should indicate a discharge ( - ) condition. 2. If ammeter pointer does not move, check ammeter terminals for proper connection and check for open circuit in wiring harness. If connections and wiring harness are satisfactory, ammeter is defective. 3. If ammeter indicates a charge (+) condition, wiring harness connections are reversed at ammeter. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Locations Audible Warning Device: Locations LH Side Of I/P Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Clock > Component Information > Testing and Inspection Clock: Testing and Inspection Regulation of electric clocks is accomplished automatically by resetting the time. If the clock is running fast, the action of turning the hands back to correct the time will automatically cause the clock to run slightly slower. If the clock is running slow, the action of turning the hands forward to correct the time will automatically cause the clock to run slightly faster (10 to 15 seconds daily). A lockout feature prevents the clock regulator mechanism from being reset more than once per wind cycle, regardless of the number of times the time is reset. After the clock rewinds, if the time is then reset, automatic regulation will take place. If a clock varies over 10 minutes per day, it will never adjust properly and must be repaired or replaced. WINDING CLOCK WHEN CONNECTING BATTERY OR CLOCK WIRING The clock requires special attention when reconnecting a battery that has been disconnected for any reason, a clock that has been disconnected, or when replacing a blown clock fuse. It is very important that the initial wind be fully made. The procedure is as follows: 1. Make sure that all other instruments and lights are turned off. 2. Connect positive cable to battery. 3. Before connecting the negative cable, press the terminal to its post on the battery. Immediately afterward, strike the terminal against the battery post to see if there is a spark. If there is a spark, allow the clock to run down until it stops ticking, and repeat as above until there is no spark. Then immediately make the permanent connection before the clock can again run down. The clock will run down in approximately two minutes. 4. Reset clock after all connections have been made. The foregoing procedure should also be followed when reconnecting the clock after it has been disconnected, or if it has stopped because of a blown fuse. Be sure to disconnect battery before installing a new fuse. TROUBLESHOOTING If clock does not run, check for blown ``clock'' fuse. If fuse is blown, check for short in wiring. If fuse is not blown, check for open circuit. With an electric clock, the most frequent cause of clock fuse blowing is voltage at the clock which will prevent a complete wind and allow clock contacts to remain closed. This may be caused by any of the following: discharged battery, corrosion on contact surface of battery terminals, loose connections at battery terminals, at junction block, at fuse clips, or at terminal connection of clock. Therefore, if in reconnecting battery or clock it is noted that the clock is not ticking, always check for blown fuse, or examine the circuits at the points indicated above to determine and correct the cause. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations Door Switch: Locations Inside Driver's Door Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Distance/Mileage Module > Component Information > Locations Fuel Distance/Mileage Module: Locations Near ECA Under RH Side Of I/P Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Component Information > Service and Repair Instrument Cluster / Carrier: Service and Repair Fig. 8 Instrument Cluster E-100---350 1. Disconnect battery ground cable. 2. Remove steering column shroud. 3. On models equipped with tilt steering column, loosen column-to-band C support to provide sufficient clearance for cluster removal. 4. On all models, remove 7 instrument cluster-to-instrument panel attaching screws. 5. Pull cluster back from panel and disconnect speedometer cable. It may be necessary to disconnect speedometer cable from transmission to provide access to the quick disconnect on the cluster. 6. Disconnect electrical connector from printed circuit board and remove cluster from vehicle, Fig. 9. 7. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Speedometer/Odometer - Inaccurate Readings Odometer: Technical Service Bulletins Speedometer/Odometer - Inaccurate Readings SPEEDOMETER - MECHANICAL/ELECTRONIC - INACCURATE SPEED READINGS AND ODOMETER READINGS Article No. 89-2-7 FORD: 1989 AND PRIOR ALL CAR LINES LINCOLN-MERCURY: 1989 AND PRIOR ALL CAR LINES LIGHT TRUCK: 1989 AND PRIOR ALL TRUCK LINES ISSUE: The accuracy of speedometer/odometer readings may be influenced by several vehicle components or systems. The information in this TSB article is intended to assist technicians in speedometer/odometer concern diagnosis. ACTION: Use the following supplemental information below to assist in speedometer/odometer diagnostics. OPERATION A mechanical analog speedometer displays vehicle speed and the odometer displays total distance traveled. The speedometer/odometer assembly is cable driven by either a transmission or a transaxle. All speedometer/odometer assemblies, except for police vehicles are the same with respect to the speed accuracy tolerance used during calibration. The odometer gear ratio is fixed so that all are identical and have no error in the speedometer head. Electronic digital operation is similar. It could use a drive cable or a speed sensor to drive the speedometer/odometer. An electronic signal is sent from a speed sensor to the digital speedometer/ odometer assembly. The speed sensor is driven by a transmission or a transaxle, similar to a cable. Several areas of concern that may affect speedometer/ odometer readings are tires, axle gear ratio and speedometer/odometer drive and driven gears. TIRES Improper tire rolling radius and inflation pressure, temperature and size may contribute to inaccurate system readings. System accuracy testing should be performed after the tires are set at the correct pressure as shown on the safety compliance certification label. The tires should be warmed for a short period. Best results are obtained on smooth, dry pavement while driving at a constant speed within the posted speed limit. AXLE/TRANSAXLE RATIO The gear ratio of the rear axle or the final drive ratio of the transaxle must be known to select or check if the proper speedometer/odometer drive and driven gears are present. Various gear ratios are available, but usually are not a concern when dealing with speedometer/odometer concerns unless the gear ratio has been changed. WARNING: NEVER CORRECT SPEEDOMETER READINGS BY CHANGING GEARS UNLESS THE ODOMETER IS ALSO OFF. DRIVE/DRIVEN GEARS The speedometer/odometer drive gear is located inside the transmission, transaxle or transfer case and is not easily accessed for change. The driven gear rotates the speedometer cable. Rear wheel drive vehicles have several driven gears with various numbers of teeth available to correct input to the speedometer/odometer head. Front wheel drive vehicles generally do not offer different gears for correction. GENERAL DESCRIPTION The maximum allowable odometer system accuracy error is +/- 3.75% of the actual distance traveled. Ford Motor vehicles are well within those limits. The speed indication is biased high, except on police vehicles with certified calibration speedometers/ odometers. As a general rule, the indicated speed is equal to or greater than the actual speed. This is intended to protect the consumer against violating speed laws. Most customer concerns are related to speedometers reading too high at true speeds between 50 MPH and 65 MPH (80 - 105 Km/h). At that speed range, the worst case errors may indicate a speed that is 10% greater than true speed. The speedometer head is an instrument which processes information sent to it by the rotating speedometer cable. If the system components send the Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Speedometer/Odometer - Inaccurate Readings > Page 3242 wrong number of revolution per mile to the speedometer head, an inaccurate speed reading and amount of distanced traveled will be displayed. Since there is no error in the fixed gear ratio of the speedometer head odometer, start by checking the accuracy of the odometer even if the customer concern indicates a speed accuracy problem. Odometer accuracy can be checked by using roads established at mile increments or a known local course. If roads with mile markers are used, a five mile stretch is recommended to allow for inaccuracies. If an error is greater than 3.75%, a change to the transmission drive/driven gear selection, tire size, or tire inflation may need attention. The odometer should be checked again to verify any corrective action. If the indicated speed error exceeds 10% between 50 MPH and 60 MPH (80 - 105 Km/h), replace the speedometer/odometer assembly. Vehicles with transfer cases that have fluctuating readings may be due to slippage of drive gears, parts not splined or loose yoke nuts. If the vehicle has speed control, the speed accuracy can be checked using the verified odometer vs. time. The formula is as follows: 3600 divided by TIME (seconds to cover one mile) = TRUE MPH (Km/h) EXAMPLES: 60 MPH (96 Km/h) requires 60 seconds to cover one mile 55 MPH (88 Km/h) requires 65 and 3/4 seconds to cover one mile 50 MPH (80 Km/h) requires 72 seconds to cover one mile ARTICLE SUPERSEDED: 84-14-6, date 7/3/84 WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 2300, 2310, 2400, 2500 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Testing and Inspection Oil Pressure Gauge: Testing and Inspection This oil pressure indicating system incorporates an instrument voltage regulator, electrical oil pressure gauge and a sending unit which are connected in series. The sending unit consists of a diaphragm, contact and a variable resistor. As oil pressure increases or decreases, the diaphragm actuated the contact on the variable resistor, in turn controlling current flow to the gauge. When oil pressure is low, the resistance of the variable resistor is high, restricting current flow to the gauge, in turn indicating low oil pressure. As oil pressure increases, the resistance of the variable resistor is lowered, permitting an increased current flow to the gauge, resulting in an increased gauge reading. TROUBLESHOOTING A special tester is required to diagnose this type gauge. Follow instructions included with the tester. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Switch <--> [Oil Pressure Sender] > Component Information > Locations Oil Pressure Switch: Locations LH Lower Front Of Engine Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Testing and Inspection Oil Pressure Warning Lamp/Indicator: Testing and Inspection Many trucks utilize a warning light on the instrument panel in place of the conventional dash indicating gauge to warn the driver when the oil pressure is dangerously low. The warning light is wired in series with the ignition switch and the engine unit--which is an oil pressure switch. The oil pressure switch contains a diaphragm and a set of contacts. When the ignition switch is turned on, the warning light circuit is energized and the circuit is completed through the closed contacts in the pressure switch. When the engine is started, build-up of oil pressure compresses the diaphragm, opening the contacts, thereby breaking the circuit and putting out the light. TROUBLESHOOTING The oil pressure warning light should go on when the ignition is turned on. If it does not light, disconnect the wire from the engine unit and ground the wire to the frame or cylinder block. Then if the warning light still does not go on with the ignition switch on, replace the bulb. If the warning light goes on when the wire is grounded to the frame or cylinder block, the engine unit should be checked for being loose or poorly grounded. If the unit is found to be tight and properly grounded, it should be removed and a new one installed. (The presence of sealing compound on the threads of the engine unit will cause a poor ground). If the warning light remains lit when it normally should be out, replace the engine unit before proceeding further to determine the cause for a low pressure indication. The warning light will sometimes light up or flicker when the engine is idling, even though the oil pressure is adequate. However, the light should go out when the engine speed is increased. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Top Of Parking Brake Assembly Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Fuel Distance/Mileage Module > Component Information > Locations Fuel Distance/Mileage Module: Locations Near ECA Under RH Side Of I/P Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations Door Switch: Locations Inside Driver's Door Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Top Of Parking Brake Assembly Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Cable > Component Information > Testing and Inspection Speedometer Cable: Testing and Inspection The following material covers only that service on speedometers which is feasible to perform. Repairs on the units themselves are not included as they require special tools and extreme care when making repairs and adjustments that only an experienced speedometer mechanic should attempt. The speedometer has two main parts, the speedometer head and the speedometer drive cable. When the speedometer fails to indicate speed or mileage, the cable or cable housing is probably broken. On vehicles are equipped with speed control, there is a speed sensor attached to the transmission. This is used to sense the revolutions of cable assembly and to regulate speed control. SPEEDOMETER CABLE Most cables are broken due to lack of lubrication, or a sharp bend or kink in the housing. A cable might break because of the speedometer head mechanism binds. In such cases, the speedometer head should be repaired or replaced before a new cable or housing is installed. A ``jumpy'' pointer condition, together with a scraping noise, is due, in most instances, to a dry or kinked speedometer cable. The kinked cable rubs on the housing and winds up, slowing down the pointer. The cable then unwinds and the pointer ``jumps.'' To check for kinks, remove the cable, lay it on a flat surface and twist one end with the fingers. If it turns over smoothly the cable is not kinked. But if part of the cable flops over as it is twisted, the cable is kinked and should be replaced. LUBRICATION The speedometer cable should be lubricated with special cable lubricant. Fill the ferrule on the upper end of the housing with the cable lubricant. Insert the cable in the housing, starting at the upper end. Turn the cable around carefully while feeding it into the housing. Repeat filling the ferrule except for the last six inches of cable. Too much lubricant at this point may cause the lubricant to work into the speedometer head. INSTALLING CABLE During installation, if the cable sticks when inserted in the housing and will not go through, the housing is damaged inside or kinked. Be sure to check the housing from one end to the other. Straighten any sharp bends by relocating clamps or elbows. Replace housing if it is badly kinked or broken. Position the cable and housing so that they lead into the head as straight as possible. Check the new cable for kinks before installing it. Use wide, sweeping, gradual curves where the cable comes out of the transmission and connects to the head so the cable will not be damaged during installation. Arrange the housing so it does not lean against the engine because heat from the engine may dry out the lubricant. If inspection indicates that the cable and housing are in good condition, yet pointer action is erratic, check the speedometer head for possible binding. The speedometer drive pinion should also be checked. If the pinion is dry or its teeth are stripped, the speedometer may not register properly. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Speedometer/Odometer - Inaccurate Readings Speedometer Head: Technical Service Bulletins Speedometer/Odometer - Inaccurate Readings SPEEDOMETER - MECHANICAL/ELECTRONIC - INACCURATE SPEED READINGS AND ODOMETER READINGS Article No. 89-2-7 FORD: 1989 AND PRIOR ALL CAR LINES LINCOLN-MERCURY: 1989 AND PRIOR ALL CAR LINES LIGHT TRUCK: 1989 AND PRIOR ALL TRUCK LINES ISSUE: The accuracy of speedometer/odometer readings may be influenced by several vehicle components or systems. The information in this TSB article is intended to assist technicians in speedometer/odometer concern diagnosis. ACTION: Use the following supplemental information below to assist in speedometer/odometer diagnostics. OPERATION A mechanical analog speedometer displays vehicle speed and the odometer displays total distance traveled. The speedometer/odometer assembly is cable driven by either a transmission or a transaxle. All speedometer/odometer assemblies, except for police vehicles are the same with respect to the speed accuracy tolerance used during calibration. The odometer gear ratio is fixed so that all are identical and have no error in the speedometer head. Electronic digital operation is similar. It could use a drive cable or a speed sensor to drive the speedometer/odometer. An electronic signal is sent from a speed sensor to the digital speedometer/ odometer assembly. The speed sensor is driven by a transmission or a transaxle, similar to a cable. Several areas of concern that may affect speedometer/ odometer readings are tires, axle gear ratio and speedometer/odometer drive and driven gears. TIRES Improper tire rolling radius and inflation pressure, temperature and size may contribute to inaccurate system readings. System accuracy testing should be performed after the tires are set at the correct pressure as shown on the safety compliance certification label. The tires should be warmed for a short period. Best results are obtained on smooth, dry pavement while driving at a constant speed within the posted speed limit. AXLE/TRANSAXLE RATIO The gear ratio of the rear axle or the final drive ratio of the transaxle must be known to select or check if the proper speedometer/odometer drive and driven gears are present. Various gear ratios are available, but usually are not a concern when dealing with speedometer/odometer concerns unless the gear ratio has been changed. WARNING: NEVER CORRECT SPEEDOMETER READINGS BY CHANGING GEARS UNLESS THE ODOMETER IS ALSO OFF. DRIVE/DRIVEN GEARS The speedometer/odometer drive gear is located inside the transmission, transaxle or transfer case and is not easily accessed for change. The driven gear rotates the speedometer cable. Rear wheel drive vehicles have several driven gears with various numbers of teeth available to correct input to the speedometer/odometer head. Front wheel drive vehicles generally do not offer different gears for correction. GENERAL DESCRIPTION The maximum allowable odometer system accuracy error is +/- 3.75% of the actual distance traveled. Ford Motor vehicles are well within those limits. The speed indication is biased high, except on police vehicles with certified calibration speedometers/ odometers. As a general rule, the indicated speed is equal to or greater than the actual speed. This is intended to protect the consumer against violating speed laws. Most customer concerns are related to speedometers reading too high at true speeds between 50 MPH and 65 MPH (80 - 105 Km/h). At that speed range, the worst case errors may indicate a speed that is 10% greater than true speed. The speedometer head is an instrument which processes information sent to it by the rotating speedometer cable. If the system components send the Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Speedometer/Odometer - Inaccurate Readings > Page 3273 wrong number of revolution per mile to the speedometer head, an inaccurate speed reading and amount of distanced traveled will be displayed. Since there is no error in the fixed gear ratio of the speedometer head odometer, start by checking the accuracy of the odometer even if the customer concern indicates a speed accuracy problem. Odometer accuracy can be checked by using roads established at mile increments or a known local course. If roads with mile markers are used, a five mile stretch is recommended to allow for inaccuracies. If an error is greater than 3.75%, a change to the transmission drive/driven gear selection, tire size, or tire inflation may need attention. The odometer should be checked again to verify any corrective action. If the indicated speed error exceeds 10% between 50 MPH and 60 MPH (80 - 105 Km/h), replace the speedometer/odometer assembly. Vehicles with transfer cases that have fluctuating readings may be due to slippage of drive gears, parts not splined or loose yoke nuts. If the vehicle has speed control, the speed accuracy can be checked using the verified odometer vs. time. The formula is as follows: 3600 divided by TIME (seconds to cover one mile) = TRUE MPH (Km/h) EXAMPLES: 60 MPH (96 Km/h) requires 60 seconds to cover one mile 55 MPH (88 Km/h) requires 65 and 3/4 seconds to cover one mile 50 MPH (80 Km/h) requires 72 seconds to cover one mile ARTICLE SUPERSEDED: 84-14-6, date 7/3/84 WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 2300, 2310, 2400, 2500 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Testing and Inspection > Dash Gauge Test Temperature Gauge: Testing and Inspection Dash Gauge Test Gauge failures are often caused by defective wiring or grounds. The first step in locating trouble should be a thorough inspection of all wiring, terminals and printed circuits. If wiring is secured by clamps, check to see whether the insulation has been severed, thereby grounding the wire. In the case of a fuel gauge installation, rust may cause failure by corrosion at the ground connection of the tank unit. The Constant Voltage Regulator (CVR) type indicator is a bimetal-resistance type system consisting of an Instrument Voltage Regulator (IVR), an indicator gauge, and a variable resistance sending unit. Current to the system is applied to the gauge terminals by the IVR, which maintains an average-pulsating value of 5 volts. The indicator gauge consists of a pointer which is attached to a wire-wound bimetal strip. Current passing through the coil heats the bimetal strip, causing the pointer to move. As more current passes through the coil, heat increases, moving the pointer farther. The circuit is completed through a sending unit which contains a variable resistor. When resistance is high, less current is allowed to pass through the gauge, and the pointer moves very little. As resistance decreases due to changing conditions in system being monitored, more current passes through gauge coil, causing pointer to move farther. Do not apply battery voltage to system or ground output terminals of IVR, as damage to system components or wiring circuits may result. DASH GAUGE TEST 1. Disconnect battery ground cable and remove gauge from vehicle. 2. Connect ohmmeter between gauge terminals and read coil winding resistance. 3. An upward movement of ohmmeter needle from 10 ohms to 14 ohms is normal, as test current of ohmmeter causes a temperature rise in gauge coil windings. 4. If ohmmeter reads below 10 ohms or above 14 ohms, gauge is defective. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Testing and Inspection > Dash Gauge Test > Page 3278 Temperature Gauge: Testing and Inspection Electrical Temperature Gauges This temperature indicating system consists of a sending unit, located on the cylinder head, electrical temperature gauge and an instrument voltage regulator. As engine temperature increases or decreases, the resistance of the sending unit changes, in turn controlling current flow to the gauge. When engine temperature is low, the resistance of the sending unit is high, restricting current flow to the gauge, in turn indicating low engine temperature. As engine temperature increases, the resistance of the ending unit decreases, permitting an increased current flow to the gauge, resulting in an increased temperature reading. TROUBLESHOOTING A special tester is required to diagnose this type gauge. Follow instructions included with the tester. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Testing and Inspection Temperature Warning Lamp/Indicator: Testing and Inspection A bimetal temperature switch located in the cylinder head control the operation of a temperature indicator light with a red lens. If the engine cooling system is not functioning properly and coolant temperature exceeds a predetermined value, the warning light will illuminate. TROUBLESHOOTING If the red light is not lit when the engine is being cranked, check for a burned out bulb, an open in the light circuit, or a defective ignition switch. If the red light is lit when the engine is running, check the wiring between light and switch for a ground, defective temperature switch, or overheated cooling system. As a test circuit to check whether the red bulb is functioning properly, a wire which is connected to the ground terminal of the ignition switch is tapped into its circuit. When the ignition is in the ``Start'' (engine cranking) position, the ground terminal is grounded inside the switch and the red bulb will be lit. When the engine is started and the ignition switch is in the ``On'' position, the test circuit is opened and the bulb is then controlled by the temperature switch. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Testing and Inspection Volt Meter Gauge: Testing and Inspection The voltmeter is a gauge which measures the electrical flow from the battery to indicate whether the battery output is within tolerances. The voltmeter reading can range from 13.5---14.0 volts under normal operating conditions. If an undercharge or overcharge condition is indicated for an extended period, the battery and charging system should be checked. TROUBLESHOOTING To check voltmeter, turn key and headlights on with engine off. Pointer should move to 12.5 volts. If no needle movement is observed, check connections from battery to circuit breaker. If connections are tight and meter shows no movement, check wire continuity. If wire continuity is satisfactory, the meter is inoperative and must be replaced. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Automatic Transmission Backup Lamp Switch: Locations Automatic Transmission Attached To Base Of Steering Column Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Automatic Transmission > Page 3291 Backup Lamp Switch: Locations Manual Transmission Attached To Shifter Assembly Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations > Automatic Transmission > Page 3292 Backup Lamp Switch: Locations 3-Speed Manual Transmission Near Dash Panel Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Locations Brake Lamp: Locations Turn/Stop/Hazard Lamps Component Locations Hazard Flasher .................................................................................................................................... ............................................................ LH side of I/P Stop Light Switch ................................................................................................................................. ...................................... Top of brake pedal support Turn Signal Flasher ............................................................................................................................. ........................................................... LH side of I/P Turn/Hazard Switch ......................................................................................................................................................... Upper LH side of steering column Connector C110 ............................................................................................................................................................ LH side of rear frame crossmember Connector C308 .................................................................................................................................................... At LH side of rear frame crossmember ... Connector C309 .................................................................................................................................................... At RH side of rear frame crossmember ... Connector C310 .................................................................................................................................. ..................................... Upper LH side of dash panel Connector C315 ............................................................................................................................................................ LH side of I/P near steering column Connector C727 .................................................................................................................................. .................................... Lower LH side of dash panel Connector C914 ......................................................................................................................................................... Below fuel tank select valve solenoid Connector C921 ............................................................................................................................................................. LH rear under frame, near fuel tank Ground G203 .......................................................................................................................................................... Behind I/P on steering column support . Ground G501 ....................................................................................................................................................... Attached to LH fender above marker light Ground G502 ....................................................................................................................................................... Attached to RH fender above marker light Ground G601 ....................................................................................................................................... .................................... Lower LH rear quarter panel Ground G603 ....................................................................................................................................... ................................... Lower RH rear quarter panel Several images for locations are given at the Lighting And Horns System level under the various connector numbers. See: Locations/Connector Locations Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Locations > Page 3296 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Locations > Page 3297 Brake Lamp: Description and Operation How The Circuit Works Stop Lights Current flows through Fuse 8 to the rear Turn/Stop Lights when the Stop Light Switch is closed. The same rear lights are used for Stop and Turn Lights (controlled by turn switch). Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations Top Of Brake Pedal Support Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 3301 Brake Light Switch: Service and Repair Fig. 6 Stop light switch replacement. Exc. 1980---83 E-100 w/manual brakes. Fig. 7 Stop light switch replacement. 1980---83 E-100 w/manual brakes 1. Disconnect battery ground cable. 2. Disconnect electrical connector from switch, Figs. 6 and 7. 3. Remove hairpin retainer, then slide stop light switch, pushrod, nylon washers and bushings away from pedal and remove the switch from vehicle. 4. Reverse procedure to install. Ensure stop light switch wires are of sufficient length to allow full travel of the brake pedal. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations Door Switch: Locations Inside Driver's Door Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Locations Hazard Warning Lamps: Locations Turn/Stop/Hazard Lamps Component Locations Hazard Flasher .................................................................................................................................... ............................................................ LH side of I/P Stop Light Switch ................................................................................................................................. ...................................... Top of brake pedal support Turn Signal Flasher ............................................................................................................................. ........................................................... LH side of I/P Turn/Hazard Switch ......................................................................................................................................................... Upper LH side of steering column Connector C110 ............................................................................................................................................................ LH side of rear frame crossmember Connector C308 .................................................................................................................................................... At LH side of rear frame crossmember ... Connector C309 .................................................................................................................................................... At RH side of rear frame crossmember ... Connector C310 .................................................................................................................................. ..................................... Upper LH side of dash panel Connector C315 ............................................................................................................................................................ LH side of I/P near steering column Connector C727 .................................................................................................................................. .................................... Lower LH side of dash panel Connector C914 ......................................................................................................................................................... Below fuel tank select valve solenoid Connector C921 ............................................................................................................................................................. LH rear under frame, near fuel tank Ground G203 .......................................................................................................................................................... Behind I/P on steering column support . Ground G501 ....................................................................................................................................................... Attached to LH fender above marker light Ground G502 ....................................................................................................................................................... Attached to RH fender above marker light Ground G601 ....................................................................................................................................... .................................... Lower LH rear quarter panel Ground G603 ....................................................................................................................................... ................................... Lower RH rear quarter panel Several images for locations are given at the Lighting And Horns System level under the various connector numbers. See: Locations/Connector Locations Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Locations > Page 3308 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Component Information > Locations > Page 3309 Hazard Warning Lamps: Description and Operation How The Circuit Works Hazard Lights Current flows through Fuse 8 to the Turn Lights and Turn Indicators when the hazard switch is pulled out. The turn switch sends current to both the RH and LH Turn Lights at the same time. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations Headlamp Dimmer Switch: Locations LH Floor Board Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Service and Repair Headlamp Switch: Service and Repair Fig. 5 Light Switch E-100---350 1. Disconnect battery ground cable. 2. Remove knob and shaft assembly by depressing release button on switch housing and pulling straight out. 3. Remove bezel or mounting nut from switch, Fig. 4. 4. Disconnect electrical connector from switch and remove switch from vehicle. 5. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations Horn Relay: Locations Horn Relay Location Under LH Side Of I/P. Under LH Side Of I/P, With Speed Control Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 3321 Underneath LH Side Of I/P Below LH Side Of I/P Horn Relay With Speed Control Bronco F-150 thru F-350, E-150 thru E-350 and Super F Series The horn relay is use on vehicles equipped with speed control and is located under the left side of the instrument panel, left of the steering column and is mounted on the outboard attaching screw of the speed control amplifier module. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 3322 Horn Relay: Testing and Inspection Fig. 3 Speed control wiring diagram. 1981---83 E-100-350 & 1984-87 E-150-350 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 3323 Fig. 4 Speed control wiring diagram. 1981 F-100-350 & Bronco Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 3324 Fig. 5 Speed control wiring diagram. 1982---83 F-100-350, 1984---87 F-150-350 & 1982---87 Bronco 1981-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986-87 Aerostar 1. Locate horn relay wire connector marked X and Y, Figs. 3, 4 and 5. 2. Using connector X, locate wire 460, then using a suitable voltmeter, check for battery voltage at male side of connector. 3. Using connector Y, locate wire 1, then using a suitable voltmeter, check for battery voltage at female side of connector. Depress horn, voltmeter should read zero and horn should sound. If battery voltage remains, circuit is open. Connectors should remain connected during testing. 4. Check horn relay by momentarily grounding circuit 1 to chassis. This bypasses horn switch and horn should sound. If horn does not sound, check for battery voltage at connector X wire 6 during relay operation. If voltage is present at circuit 6 during relay operation, an open circuit is indicated between horn and connector X. 5. If relay does not operate with battery voltage present at circuit 460 and circuit 1 is grounded, replace relay. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Locations License Plate Lamp: Locations Exterior Lamps Component Locations Button Connectors ............................................................................................................................... ................................ Rear doors and rear door jamb Light Switch ......................................................................................................................................... ................................... I/P, to left of steering column Connector C110 ............................................................................................................................................................ LH side of rear frame crossmember Connector C303 .................................................................................................................................. .................................... Lower LH side of dash panel Connector C308 .................................................................................................................................................... At LH side of rear frame crossmember ... Connector C309 .................................................................................................................................................... At RH side of rear frame crossmember ... Connector C310 .................................................................................................................................. ..................................... Upper LH side of dash panel Connector C411 .................................................................................................................................. .................................... LH side of I/P at light switch Ground G501 ....................................................................................................................................................... Attached to LH fender above marker light Ground G502 ....................................................................................................................................................... Attached to RH fender above marker light Ground G601 ....................................................................................................................................... .................................... Lower LH rear quarter panel Ground G603 ....................................................................................................................................... .................................... Lower RH rear quarter panel Ground G954 ....................................................................................................................................... ............................. LH rear door, above license lights Several images for locations are given at the Lighting And Horns System level under the various connector numbers. See: Locations/Connector Locations Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Locations > Page 3328 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Locations Marker Lamp: Locations Exterior Lamps Component Locations Button Connectors ............................................................................................................................... ................................ Rear doors and rear door jamb Light Switch ......................................................................................................................................... ................................... I/P, to left of steering column Connector C110 ............................................................................................................................................................ LH side of rear frame crossmember Connector C303 .................................................................................................................................. .................................... Lower LH side of dash panel Connector C308 .................................................................................................................................................... At LH side of rear frame crossmember ... Connector C309 .................................................................................................................................................... At RH side of rear frame crossmember ... Connector C310 .................................................................................................................................. ..................................... Upper LH side of dash panel Connector C411 .................................................................................................................................. .................................... LH side of I/P at light switch Ground G501 ....................................................................................................................................................... Attached to LH fender above marker light Ground G502 ....................................................................................................................................................... Attached to RH fender above marker light Ground G601 ....................................................................................................................................... .................................... Lower LH rear quarter panel Ground G603 ....................................................................................................................................... .................................... Lower RH rear quarter panel Ground G954 ....................................................................................................................................... ............................. LH rear door, above license lights Several images for locations are given at the Lighting And Horns System level under the various connector numbers. See: Locations/Connector Locations Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Locations > Page 3332 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Locations > Page 3333 Marker Lamp: Description and Operation How The Circuit Works Turn Lights With the Ignition Switch in RUN, current can flow through Fuse 11, the Turn Signal Flasher, Turn/Hazard Switch, and on to the Turn Lights and Turn Indicators. The turn switch sends the power to either the LH or RH Turn Lights. Stop Lights Current flows through Fuse 8 to the rear Turn/Stop Lights when the Stop Light Switch is closed. The same rear lights are used for Stop and Turn Lights (controlled by turn switch). Hazard Lights Current flows through Fuse 8 to the Turn Lights and Turn Indicators when the hazard switch is pulled out. The turn switch sends current to both the RH and LH Turn Lights at the same time. For Troubleshooting hints, refer to Marker Lamp Testing and Inspection procedures. See: Testing and Inspection Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Testing and Inspection > Backup Lamps Marker Lamp: Testing and Inspection Backup Lamps Troubleshooting Hints No Backup Lights Work Check Fuse 11 by operating the Turn Lights. - Separate C305 With gearshift in REVERSE, check continuity through PRNDL or Backup Switch, at BK/R wires. One Backup Lamp Will Not Work Check bulb. - Check socket for corrosion. - Check voltage at socket hot pin. - Check continuity to ground. Backup Lights Stay ON Check adjustment, or replace switch. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Testing and Inspection > Backup Lamps > Page 3336 Marker Lamp: Testing and Inspection Headlights/Marker/Park/License Troubleshooting Hints No Headlights/Park Lights ON Check for voltage at R/Y wire of Dimmer Switch. If bad, check continuity of wire and Light Switch - Check continuity of Dimmer Switch. Replace if bad No Hi And Lo Beam On One Side Make sure ground connection on that side is clean and tight No Exterior Lights Look for frayed or damaged wires, or loose connections - Make sure C411 is tight. - Check for voltage at BK/O wire of Light Switch. If bad, check harness back to Battery. - If Instrument Illumination lights work, check continuity of BR wire in harness. - If no instrument lights work, check continuity of Light Switch. One Light Does Not Work Check bulb. - Check for frayed or damaged wires, or loose connections. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Testing and Inspection > Backup Lamps > Page 3337 Marker Lamp: Testing and Inspection Turn/Stop/Hazard Lamps Troubleshooting Hints Hazard Flasher Doesn't Work Check Fuse 8 by operating Stop Lights. - Check voltage at Hazard Flasher R/W wire. - Replace Hazard Flasher. - Check voltage at C315. - Replace Turn/Hazard Switch. Turn Indicators Don't Work Check Fuse 11 by operating Backup Lights. - Replace Turn Signal Flasher. - Check voltage of Turn Signal Flasher O/Y wire. - Repair or replace Turn/Hazard Switch. No Front Or Rear Lights Check ground points are tight and not corroded. One Turn Light Not Operating Check for burned-out bulb. - Check voltage and ground at bulb socket. - Check for frayed or damaged wires. - Check that connectors are not corroded. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Locations Parking Lamp: Locations Exterior Lamps Component Locations Button Connectors ............................................................................................................................... ................................ Rear doors and rear door jamb Light Switch ......................................................................................................................................... ................................... I/P, to left of steering column Connector C110 ............................................................................................................................................................ LH side of rear frame crossmember Connector C303 .................................................................................................................................. .................................... Lower LH side of dash panel Connector C308 .................................................................................................................................................... At LH side of rear frame crossmember ... Connector C309 .................................................................................................................................................... At RH side of rear frame crossmember ... Connector C310 .................................................................................................................................. ..................................... Upper LH side of dash panel Connector C411 .................................................................................................................................. .................................... LH side of I/P at light switch Ground G501 ....................................................................................................................................................... Attached to LH fender above marker light Ground G502 ....................................................................................................................................................... Attached to RH fender above marker light Ground G601 ....................................................................................................................................... .................................... Lower LH rear quarter panel Ground G603 ....................................................................................................................................... .................................... Lower RH rear quarter panel Ground G954 ....................................................................................................................................... ............................. LH rear door, above license lights Several images for locations are given at the Lighting And Horns System level under the various connector numbers. See: Locations/Connector Locations Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Locations > Page 3341 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations Horn Relay: Locations Horn Relay Location Under LH Side Of I/P. Under LH Side Of I/P, With Speed Control Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 3346 Underneath LH Side Of I/P Below LH Side Of I/P Horn Relay With Speed Control Bronco F-150 thru F-350, E-150 thru E-350 and Super F Series The horn relay is use on vehicles equipped with speed control and is located under the left side of the instrument panel, left of the steering column and is mounted on the outboard attaching screw of the speed control amplifier module. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 3347 Horn Relay: Testing and Inspection Fig. 3 Speed control wiring diagram. 1981---83 E-100-350 & 1984-87 E-150-350 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 3348 Fig. 4 Speed control wiring diagram. 1981 F-100-350 & Bronco Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component Information > Locations > Page 3349 Fig. 5 Speed control wiring diagram. 1982---83 F-100-350, 1984---87 F-150-350 & 1982---87 Bronco 1981-87 Models Exc. 1983-87 Ranger, 1984-87 Bronco II & 1986-87 Aerostar 1. Locate horn relay wire connector marked X and Y, Figs. 3, 4 and 5. 2. Using connector X, locate wire 460, then using a suitable voltmeter, check for battery voltage at male side of connector. 3. Using connector Y, locate wire 1, then using a suitable voltmeter, check for battery voltage at female side of connector. Depress horn, voltmeter should read zero and horn should sound. If battery voltage remains, circuit is open. Connectors should remain connected during testing. 4. Check horn relay by momentarily grounding circuit 1 to chassis. This bypasses horn switch and horn should sound. If horn does not sound, check for battery voltage at connector X wire 6 during relay operation. If voltage is present at circuit 6 during relay operation, an open circuit is indicated between horn and connector X. 5. If relay does not operate with battery voltage present at circuit 460 and circuit 1 is grounded, replace relay. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Trailer Lighting Relay > Component Information > Locations Trailer Lighting Relay: Locations LH Rear Fender Below LH Taillight Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Automatic Transmission Backup Lamp Switch: Locations Automatic Transmission Attached To Base Of Steering Column Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Automatic Transmission > Page 3358 Backup Lamp Switch: Locations Manual Transmission Attached To Shifter Assembly Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations > Automatic Transmission > Page 3359 Backup Lamp Switch: Locations 3-Speed Manual Transmission Near Dash Panel Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations Top Of Brake Pedal Support Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 3363 Brake Light Switch: Service and Repair Fig. 6 Stop light switch replacement. Exc. 1980---83 E-100 w/manual brakes. Fig. 7 Stop light switch replacement. 1980---83 E-100 w/manual brakes 1. Disconnect battery ground cable. 2. Disconnect electrical connector from switch, Figs. 6 and 7. 3. Remove hairpin retainer, then slide stop light switch, pushrod, nylon washers and bushings away from pedal and remove the switch from vehicle. 4. Reverse procedure to install. Ensure stop light switch wires are of sufficient length to allow full travel of the brake pedal. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations Door Switch: Locations Inside Driver's Door Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations Headlamp Dimmer Switch: Locations LH Floor Board Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Service and Repair Headlamp Switch: Service and Repair Fig. 5 Light Switch E-100---350 1. Disconnect battery ground cable. 2. Remove knob and shaft assembly by depressing release button on switch housing and pulling straight out. 3. Remove bezel or mounting nut from switch, Fig. 4. 4. Disconnect electrical connector from switch and remove switch from vehicle. 5. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations Turn Signal Switch: Locations Upper LH Side Of Steering Column Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 3376 Turn Signal Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove horn switch, then the steering wheel. 3. Remove turn signal switch lever by unscrewing from steering column. 4. On 1981---87 F-100---350 and Bronco models, remove lower steering column shroud. 5. On 1981---87 E-100---350 models, remove upper and lower steering column shrouds. 6. On all models, disconnect electrical connector from turn signal switch and remove switch attaching screws. 7. On all models with tilt column and 1980 E-100---350, F-100---350 and Bronco with fixed column, remove wires and terminals from steering column electrical connector, after noting color code and location of each connector. Remove plastic cover sleeve, if equipped, from wiring harness, then lift switch assembly out through top of column. On 1981---87 E-100---350 models equipped with tilt column and automatic transmission, disconnect transmission selector indicator light electrical connector from turn signal switch harness prior to removing the switch. 8. On all models with fixed column, except 1980 E-100---350, F-100---350 and Bronco, remove switch assembly by lifting out of column while guiding connector plug through opening in shift socket. On 1981---87 E-100---350 models equipped with fixed column and automatic transmission, remove transmission selector indicator light assembly with turn signal switch. 9. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Trailer Lighting Relay > Component Information > Locations Trailer Lighting Relay: Locations LH Rear Fender Below LH Taillight Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Turn Flasher Turn Signal Flasher: Locations Turn Flasher Behind LH Side Of I/P HAZARD WARNING: Behind LH side Of I/P, On Fuse Panel TURN SIGNAL: Behind LH Side Of I/P, On Fuse Panel Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations > Turn Flasher > Page 3388 Turn Signal Flasher: Locations Turn/Hazard Flasher Behind LH Side Of I/P HAZARD WARNING: Behind LH side Of I/P, On Fuse Panel TURN SIGNAL: Behind LH Side Of I/P, On Fuse Panel Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations Turn Signal Switch: Locations Upper LH Side Of Steering Column Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 3392 Turn Signal Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove horn switch, then the steering wheel. 3. Remove turn signal switch lever by unscrewing from steering column. 4. On 1981---87 F-100---350 and Bronco models, remove lower steering column shroud. 5. On 1981---87 E-100---350 models, remove upper and lower steering column shrouds. 6. On all models, disconnect electrical connector from turn signal switch and remove switch attaching screws. 7. On all models with tilt column and 1980 E-100---350, F-100---350 and Bronco with fixed column, remove wires and terminals from steering column electrical connector, after noting color code and location of each connector. Remove plastic cover sleeve, if equipped, from wiring harness, then lift switch assembly out through top of column. On 1981---87 E-100---350 models equipped with tilt column and automatic transmission, disconnect transmission selector indicator light electrical connector from turn signal switch harness prior to removing the switch. 8. On all models with fixed column, except 1980 E-100---350, F-100---350 and Bronco, remove switch assembly by lifting out of column while guiding connector plug through opening in shift socket. On 1981---87 E-100---350 models equipped with fixed column and automatic transmission, remove transmission selector indicator light assembly with turn signal switch. 9. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Locations Power Window Relay: Locations Lower LH Cowl Near Fuse Panel Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations Power Window Motor: Locations Behind Trim Panels, Below Windows Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations Power Window Relay: Locations Lower LH Cowl Near Fuse Panel Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > Customer Interest: > 8852 > Mar > 88 > Manual Vent Windows - Difficult to Open Window Glass: Customer Interest Manual Vent Windows - Difficult to Open GLASS - MANUAL VENT WINDOWS HARD TO OPEN Article No. 88-5-2 FORD: 1980-88 CROWN VICTORIA 1981-86 THUNDERBIRD 1981-87 ESCORT 1984-86 LTD LINCOLN-MERCURY: 1980-88 GRAND MARQUIS 1981-86 LYNX, COUGAR 1984-86 MARQUIS LIGHT TRUCK: 1980-88 E-SERIES, F-SERIES, BRONCO 1983-88 RANGER 1984-88 BRONCO II 1986-88 AEROSTAR ISSUE: Hard to open pivoting type vent windows may be caused by the glass sticking to the weatherstrip on the division bar. The weatherstrip is often pulled out of the division bar when this condition is present. FIGURE 1 ACTION: To correct this, apply a strip of clear pressure sensitive tape on the inside vertical edge of the vent window glass, Figure 1. PART NUMBER PART NAME CLASS E8AZ-19627-A Clear Pressure Sensitive B Tape OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION: 880502A - Both vent windows TIME: 0.3 Hr. DLR. CODING: Basic Part No. 7021402 Code: 41 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 8852 > Mar > 88 > Manual Vent Windows - Difficult to Open Window Glass: All Technical Service Bulletins Manual Vent Windows - Difficult to Open GLASS - MANUAL VENT WINDOWS HARD TO OPEN Article No. 88-5-2 FORD: 1980-88 CROWN VICTORIA 1981-86 THUNDERBIRD 1981-87 ESCORT 1984-86 LTD LINCOLN-MERCURY: 1980-88 GRAND MARQUIS 1981-86 LYNX, COUGAR 1984-86 MARQUIS LIGHT TRUCK: 1980-88 E-SERIES, F-SERIES, BRONCO 1983-88 RANGER 1984-88 BRONCO II 1986-88 AEROSTAR ISSUE: Hard to open pivoting type vent windows may be caused by the glass sticking to the weatherstrip on the division bar. The weatherstrip is often pulled out of the division bar when this condition is present. FIGURE 1 ACTION: To correct this, apply a strip of clear pressure sensitive tape on the inside vertical edge of the vent window glass, Figure 1. PART NUMBER PART NAME CLASS E8AZ-19627-A Clear Pressure Sensitive B Tape OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION: 880502A - Both vent windows TIME: 0.3 Hr. DLR. CODING: Basic Part No. 7021402 Code: 41 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Glass: > 84219 > Oct > 84 > Wiper/Washer - Low Fluid Warning Light Stays On Washer Fluid Level Switch: All Technical Service Bulletins Wiper/Washer - Low Fluid Warning Light Stays On Article No. 84-21-9 WIPER/WASHER - LOW FLUID WARNING LIGHT STAYS ON FORD ALL MODEL YEARS AND ALL CAR LINES WITH LOW FLUID WARNING LIGHT LINCOLN-MERCURY ALL MODEL YEARS AND ALL CAR LINES WITH LOW FLUID WARNING LIGHT LIGHT TRUCKS ALL MODEL YEARS AND ALL LINES WITH LOW FLUID WARNING LIGHT On some vehicles equipped with low fluid warning light, the light may stay on even when the washer reservoir is full. This is caused by using washer fluid concentrate (C9AZ-19550-A/B) that has not been mixed with water according to the instructions. The undiluted washer solution is absorbed by the float resulting in the float sinking. When filling the washer reservoir with washer fluid concentrate (C9AZ-19550-A/B), the instructions on the can must be followed. Mixing the concentrated washer fluid with water will stop the float from sinking. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Customer Interest: > 8398 > May > 83 > Side Window - Water Leaks Window Seal: Customer Interest Side Window - Water Leaks Article No. 83-9-8 LEAKS - WATER - FLIP-OUT PRIVACY GLASS SIDE WINDOWS LIGHT TRUCKS 1982-83 ECONOLINE Figure 7 The glass frame can be distorted by the window latch, causing leaks between the glass and frame. The latch should be adjusted to use minimum locking effort to reduce the force on the frame. Additionally, applying silicone rubber sealer to the glass and frame inner and outer faces (Figure 7) will be necessary for those frames that have had this seal broken. Care must be taken when applying this sealer to produce an acceptable finished appearance. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > Customer Interest: > 8398 > May > 83 > Side Window - Water Leaks > Page 3436 OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: M TIME: "Actual Time" as defined in the Warranty and Policy Manual. DLR. CODING: Basic Part No. 7025722 Code: 45 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 8398 > May > 83 > Side Window - Water Leaks Window Seal: All Technical Service Bulletins Side Window - Water Leaks Article No. 83-9-8 LEAKS - WATER - FLIP-OUT PRIVACY GLASS SIDE WINDOWS LIGHT TRUCKS 1982-83 ECONOLINE Figure 7 The glass frame can be distorted by the window latch, causing leaks between the glass and frame. The latch should be adjusted to use minimum locking effort to reduce the force on the frame. Additionally, applying silicone rubber sealer to the glass and frame inner and outer faces (Figure 7) will be necessary for those frames that have had this seal broken. Care must be taken when applying this sealer to produce an acceptable finished appearance. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 8398 > May > 83 > Side Window - Water Leaks > Page 3442 OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION: M TIME: "Actual Time" as defined in the Warranty and Policy Manual. DLR. CODING: Basic Part No. 7025722 Code: 45 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Windows and Glass > Windows > Window Seal > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Seal: > 84219 > Oct > 84 > Wiper/Washer - Low Fluid Warning Light Stays On Washer Fluid Level Switch: All Technical Service Bulletins Wiper/Washer - Low Fluid Warning Light Stays On Article No. 84-21-9 WIPER/WASHER - LOW FLUID WARNING LIGHT STAYS ON FORD ALL MODEL YEARS AND ALL CAR LINES WITH LOW FLUID WARNING LIGHT LINCOLN-MERCURY ALL MODEL YEARS AND ALL CAR LINES WITH LOW FLUID WARNING LIGHT LIGHT TRUCKS ALL MODEL YEARS AND ALL LINES WITH LOW FLUID WARNING LIGHT On some vehicles equipped with low fluid warning light, the light may stay on even when the washer reservoir is full. This is caused by using washer fluid concentrate (C9AZ-19550-A/B) that has not been mixed with water according to the instructions. The undiluted washer solution is absorbed by the float resulting in the float sinking. When filling the washer reservoir with washer fluid concentrate (C9AZ-19550-A/B), the instructions on the can must be followed. Mixing the concentrated washer fluid with water will stop the float from sinking. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Wiper Control Module: Locations Upper LH Side Of I/P Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Technical Service Bulletins > Customer Interest for Washer Fluid Level Switch: > 84219 > Oct > 84 > Wiper/Washer - Low Fluid Warning Light Stays On Washer Fluid Level Switch: Customer Interest Wiper/Washer - Low Fluid Warning Light Stays On Article No. 84-21-9 WIPER/WASHER - LOW FLUID WARNING LIGHT STAYS ON FORD ALL MODEL YEARS AND ALL CAR LINES WITH LOW FLUID WARNING LIGHT LINCOLN-MERCURY ALL MODEL YEARS AND ALL CAR LINES WITH LOW FLUID WARNING LIGHT LIGHT TRUCKS ALL MODEL YEARS AND ALL LINES WITH LOW FLUID WARNING LIGHT On some vehicles equipped with low fluid warning light, the light may stay on even when the washer reservoir is full. This is caused by using washer fluid concentrate (C9AZ-19550-A/B) that has not been mixed with water according to the instructions. The undiluted washer solution is absorbed by the float resulting in the float sinking. When filling the washer reservoir with washer fluid concentrate (C9AZ-19550-A/B), the instructions on the can must be followed. Mixing the concentrated washer fluid with water will stop the float from sinking. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Washer Fluid Level Switch: > 84219 > Oct > 84 > Wiper/Washer - Low Fluid Warning Light Stays On Washer Fluid Level Switch: All Technical Service Bulletins Wiper/Washer - Low Fluid Warning Light Stays On Article No. 84-21-9 WIPER/WASHER - LOW FLUID WARNING LIGHT STAYS ON FORD ALL MODEL YEARS AND ALL CAR LINES WITH LOW FLUID WARNING LIGHT LINCOLN-MERCURY ALL MODEL YEARS AND ALL CAR LINES WITH LOW FLUID WARNING LIGHT LIGHT TRUCKS ALL MODEL YEARS AND ALL LINES WITH LOW FLUID WARNING LIGHT On some vehicles equipped with low fluid warning light, the light may stay on even when the washer reservoir is full. This is caused by using washer fluid concentrate (C9AZ-19550-A/B) that has not been mixed with water according to the instructions. The undiluted washer solution is absorbed by the float resulting in the float sinking. When filling the washer reservoir with washer fluid concentrate (C9AZ-19550-A/B), the instructions on the can must be followed. Mixing the concentrated washer fluid with water will stop the float from sinking. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations Wiper Switch: Locations Upper LH Side Of I/P Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 3475 Wiper Switch: Testing and Inspection Fig. 4 Wiper Switch Continuity Test Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 3476 Fig. 5 Testing wiper switch continuity. 1980 Bronco & F-100---350 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 3477 Fig. 5 Wiper Switch Continuity Test 1. Check continuity between switch terminals, Figs. 4 through 6. 2. To detect marginal operation of switch, rotate or slide switch control knob while each reading is being taken. 3. If switch does not show continuity or if poor continuity exists at any switch position, replace switch. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 3478 Wiper Switch: Service and Repair E-100---350 1. Disconnect battery ground cable. 2. Remove wiper switch knob. 3. Remove ignition switch bezel from finish panel. 4. Remove light switch knob and shaft assembly by depressing release button on switch housing and pulling straight out. 5. Remove 2 lower attaching screws from finish panel, then pry the 2 upper retainers away from instrument panel. 6. Disconnect wiper switch electrical connector, then remove switch attaching screws and the switch from vehicle. 7. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Technical Service Bulletins > Customer Interest for Washer Fluid Level Switch: > 84219 > Oct > 84 > Wiper/Washer - Low Fluid Warning Light Stays On Washer Fluid Level Switch: Customer Interest Wiper/Washer - Low Fluid Warning Light Stays On Article No. 84-21-9 WIPER/WASHER - LOW FLUID WARNING LIGHT STAYS ON FORD ALL MODEL YEARS AND ALL CAR LINES WITH LOW FLUID WARNING LIGHT LINCOLN-MERCURY ALL MODEL YEARS AND ALL CAR LINES WITH LOW FLUID WARNING LIGHT LIGHT TRUCKS ALL MODEL YEARS AND ALL LINES WITH LOW FLUID WARNING LIGHT On some vehicles equipped with low fluid warning light, the light may stay on even when the washer reservoir is full. This is caused by using washer fluid concentrate (C9AZ-19550-A/B) that has not been mixed with water according to the instructions. The undiluted washer solution is absorbed by the float resulting in the float sinking. When filling the washer reservoir with washer fluid concentrate (C9AZ-19550-A/B), the instructions on the can must be followed. Mixing the concentrated washer fluid with water will stop the float from sinking. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Washer Fluid Level Switch: > 84219 > Oct > 84 > Wiper/Washer - Low Fluid Warning Light Stays On Washer Fluid Level Switch: All Technical Service Bulletins Wiper/Washer - Low Fluid Warning Light Stays On Article No. 84-21-9 WIPER/WASHER - LOW FLUID WARNING LIGHT STAYS ON FORD ALL MODEL YEARS AND ALL CAR LINES WITH LOW FLUID WARNING LIGHT LINCOLN-MERCURY ALL MODEL YEARS AND ALL CAR LINES WITH LOW FLUID WARNING LIGHT LIGHT TRUCKS ALL MODEL YEARS AND ALL LINES WITH LOW FLUID WARNING LIGHT On some vehicles equipped with low fluid warning light, the light may stay on even when the washer reservoir is full. This is caused by using washer fluid concentrate (C9AZ-19550-A/B) that has not been mixed with water according to the instructions. The undiluted washer solution is absorbed by the float resulting in the float sinking. When filling the washer reservoir with washer fluid concentrate (C9AZ-19550-A/B), the instructions on the can must be followed. Mixing the concentrated washer fluid with water will stop the float from sinking. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Wiper Control Module: Locations Upper LH Side Of I/P Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Gear Box > Component Information > Service and Repair Wiper Gear Box: Service and Repair 1. Disconnect battery ground cable. 2. Remove both wiper arm and blade assemblies. 3. Remove cowl grille attaching screws and raise the grille slightly. 4. Disconnect windshield washer fluid hose, then remove cowl grille. 5. Remove clip securing right and left linkage and the retaining clip from wiper motor arm. 6. Remove 3 pivot body-to-cowl panel attaching screws, then the arm and pivot shaft assembly. 7. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Wiper Motor - Noisy Wiper Motor: Technical Service Bulletins Wiper Motor - Noisy Article No. 83-22-16 WIPER MOTOR - NOISY LIGHT TRUCKS 1975-83 ECONOLINE Econolines with a noisy windshield wiper motor(s) may be serviced with a newly released motor that incorporates a brush assembly that reduces motor noise. PART NUMBER PART NAME CLASS E3PZ-17508-A Wiper Motor A OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual. OPERATION/TIME: Refer to the Labor Time Standards Manual for applicable operation and time. DLR. CODING: Basic Part No. 17508 Code: 56 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Page 3502 Wiper Motor: Locations LH Side Of Dash Panel Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Page 3503 Wiper Motor: Testing and Inspection Fig. 2 Wiper Motor Current Draw Test E-100---350 Series 1. Disconnect wiper motor linkage. 2. Connect positive lead from multimeter to center terminal on motor end plate and the green lead from tester to battery positive post, Fig. 2. Motor terminals are too small to make necessary test connections without using connector sleeves and wires between motor terminals and tester. Suitable connector sleeves should be crimped onto both ends of wires. 3. Connect jumper wire from battery negative post to low speed terminal on motor end plate and read current draw, then move jumper wire from low speed terminal to high speed terminal and read current draw. 4. If current draw exceeds 3.5 amps, ensure that output arm or windlatch mechanism are not binding or damaged, and replace wiper motor. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Page 3504 Wiper Motor: Service and Repair E-100---350 1. Disconnect battery ground cable. 2. Remove fuse panel and bracket assembly. 3. Disconnect wiper motor electrical connectors from motor brush cap and gearbox cover. 4. Remove both wiper arm and blade assemblies. 5. Remove outer air inlet cowl, then the motor drive arm-to-linkage mounting arm and pivot shaft assembly retaining clip. 6. Remove wiper motor attaching bolts and the wiper motor. 7. Reverse procedure to install. Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations Wiper Switch: Locations Upper LH Side Of I/P Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 3508 Wiper Switch: Testing and Inspection Fig. 4 Wiper Switch Continuity Test Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 3509 Fig. 5 Testing wiper switch continuity. 1980 Bronco & F-100---350 Ford E 150 Van Workshop Manual (V8-351 5.8L (1982)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 3510 Fig. 5 Wiper Switch Continuity Test 1. Check continuity between switch terminals, Figs. 4 through 6. 2. To detect marginal operation of switch, rotate or slide switch control knob while each reading is being taken. 3. If switch does not show continuity or if poor continuity exists at any switch position, replace switch.